• Author / Uploaded
• subash

Citation preview

VOLUME – II

PIPELINE ENGINEERING

SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE

0

10.11.2008 DESIGN BASIS/JOB SPECIFICATION/ STANDARD SPECIFICATION/STANDARDS/ DRAWINGS/DATASHEET

REV.

DATE

INDEX Volume – II PIPELINE ENGINEERING (BIDDING DOCUMENT NO. - 8000000682)

S. NO.

TITLE

REV.

SPEC.

No. of Pages

JOB SPECIFICATION 1 2 3 4 5 6 7

Engineering Design Basis Piping Material Specification Welding Specification for Mainline for Transportation of Gas Welding Specification Chart Welding Specification Chart Specification for Geo Textile bags for Anti-Buoyancy Technical Specification for PreCommissioning and Commissioning

0 0

0001-01-04-03-001 0001-01-05-02-001

19 68

0

0001-01-04-02-001

52

0 0

0001-01-04-02-001-WSC1 0001-01-04-02-001-WSC2

01 02

0

0001-01-04-02-002

06

0

0001-01-04-02-003

15

S-04-02-001

36

S-04-02-002

43

S-04-02-003 S-04-02-004

06 34

S-04-02-005

34

S-04-02-006

31

S-04-02-007 S-04-02-008

17 14

S-04-02-012

14

S-04-02-013

07

STANDARD SPECIFICATION – PIPELINES Specification for Longitudinal 1 0 Seam Submerged Arc Welded Linepipe (Onshore) Specification for Helical (Spiral) 2 Seam Submerged Arc Welded 0 Linepipe (Onshore) 3 Specification for Seamless Pipe 0 4 Specification of ERW pipe 0 Specification of External coating 0 5 – 3L PE Coating Specification of Internal Epoxy 6 0 coating 7 Specification of Ball Valve 0 8 Specification of Plug Valve 0 Specification of Gas Powered 0 9 Valve Actuators Specification for Seamless 10 fittings & Flanges, Size up to DN 0 400 mm (16”)

Page 1 of 7

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Specification for flanges & Welded Fittings (Size DN 450 mm (18") and above Specification for Long Radius Bends for Onshore Pipelines Specification for Flow Tee (Bar Tees) for Onshore Pipeline Specification for Scraper Traps for Onshore Pipelines Specification for Pig Signaler for Onshore Pipelines Specification for Insulating Joints for Onshore Pipelines Specification for Casing Insulator and End Seals Specification for Field Joint Coating (Onshore Pipeline) Specification for Concrete Weight Coating of Onshore Pipelines Specification for Repair of Polyethylene Coating Specification for Quick Opening End Closure Specification for Pipeline River Crossings using HDD Construction of pipelines crossing Roads, Rail Roads and Minor Water Crossings Major Water Crossing Conventional Trenching Specification for Pipeline Construction (Onshore) Specification for Hydrostatic Testing of Onshore Pipelines Specification for Pipeline Markers Specification for Documentation for Pipeline Construction Specification for Blasting Specification for Detailed Pipeline Route Survey (Onshore) Welding Specification for Fabrication of Piping Spec. for Instructions to Vendor for Quality Data Requirement

0

S-04-02-014

07

0

S-04-02-015

10

0

S-04-02-016

12

0

S-04-02-017

17

0

S-04-02-018

6

0

S-04-02-019

9

0

S-04-02-020

08

0

S-04-02-021

15

0

S-04-02-022

15

0

S-04-02-023

06

0

S-04-02-024

08

0

S-04-02-025

15

0

S-04-02-026

11

0

S-04-02-027

15

0

S-04-02-028

43

0

S-04-02-029

22

0

S-04-02-030

05

0

S-04-02-031

09

0

S-04-02-032

11

0

S-04-02-033

17

0

S-04-02-034

32

0

S-04-02-035

10

Page 2 of 7

33 34

Spec. for Issue and Reconciliation of Material Spec. for Pipeline Information Management system

STANDARD SPECIFICATION – PIPING 1 Technical Notes for Pipes 2 Technical Notes for Valves Technical Notes for 3 Butt Welded, Socket Welded and Screwed Fittings Technical Notes for Flanges, 4 Spectacle Blinds and Drip legs Technical Notes for Bolts and 5 Nuts Technical Notes for 6 Gaskets Inspection and Test Plan for 7 Gaskets Standard Specification for 8 Fabrication and Erection of Piping Standard Specification of "Non9 Destructive Examination of Piping" Specification for Inspection, 10 Flushing and Testing of Piping System Specification for Shop and Field 11 Painting Standard specification of PMI at 12 Vendor's works. STANDARD DRAWING – PIPELINES Typical Right of Way for 1 Pipelines Typical Trench Dimensions for 2 Pipelines 3 Pipeline Symbols 4 Topographical Symbols Existing pipeline on sleeper 5 crossing Pipeline Road/ Highway 6 Uncased Crossing 7 Details of casing vent and drain 8 Casing pipe details

0

S-04-02-036

09

0

S-04-02-037

06

0 0

S-05-02-001 S-05-02-002

09 17

0

S-05-02-003

07

0

S-05-02-004

05

0

S-05-02-005

03

0

S-05-02-006

03

0

S-05-06-001

04

0

S-05-02-011

16

0

S-05-02-012

16

0

S-05-02-013

10

0

S-05-02-014

49

0

S-14-02-001

07

0

S-04-01-001

02

0

S-04-01-002

01

0 0

S-04-01-003 S-04-01-004

01 01

0

S-04-01-005

02

0

S-04-01-006

01

0 0

S-04-01-007 S-04-01-008

01 01 Page 3 of 7

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Existing Under Ground Pipe Crossing (Type-I) Existing Under Ground Pipe Crossing (Type-II) Under Ground Cable Crossing Over Head Power Line Crossing Typical trench dimension for two or more pipelines in common trench K.M. Post Typical ROU boundary marker Aerial marker Direction marker Pipeline Warning Sign Navigable Waterway Pipeline Crossing Warning Sign Pipeline Road/Highway Cased Crossing Typical Stream Crossings Typical Slope Breakers Details Bank Protection Details for water crossings Typical details of railway crossings Select Backfill for Station Approach Slope stabilization in ghat/ hill areas Soil stabilization in hilly areas Typical lined canal cased crossing detail Typical lined canal crossings (Uncased) Typical Cross section for ROU preparation in Hilly areas

STANDARD DRAWING – PIPING 1 Jack Screw for Spectacle Blind 2 Jack Screw for Spacer & Blind Vents & Drains on Lines 1-1/2” 3 & Below Vents & Drains on Lines 2” & 4 Above Wells Installations 1-1/2” 5 Diameter Traps 6 Pressure Tapings – PG, PT, PI,

0

S-04-01-009

02

0

S-04-01-010

02

0

S-04-01-011 S-04-01-012

02 02

0

S-04-01-013

01

0 0 0 0 0

S-04-01-014 S-04-01-015 S-04-01-016 S-04-01-017 S-04-01-018

03 02 03 03 03

0

S-04-01-019

02

0

S-04-01-020

02

0 0

S-04-01-021 S-04-01-022

02 03

0

S-04-01-023

03

0

S-04-01-024

03

0

S-04-01-026

02

0

S-04-01-027

02

0

S-04-01-028

03

0

S-04-01-029

02

0

S-04-01-030

01

0

S-04-01-031

01

0 0

S-05-01-001 S-05-01-002

01 01

0

S-05-01-003

01

0

S-05-01-004

01

0

S-05-01-005

02

0

S-05-01-006

01 Page 4 of 7

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

PA, PC etc Handle Projections for Spacers and Blinds T-Strainer Type-1 2"-4" (150# RF, 300# RF and RTJ, 600# RF and RTJ) T-Strainer Type-1 6"-24" (150# RF, 300# RF and RTJ, 600# RF and RTJ) Orientation of Orifice Traps Stub-in Standard Welding of pipe with different thickness Fillet weld details Welding details for branch connections Method of cutting and dimensions of field manufactured concentric reducers Tolerances for fabrication Pipe shoe for hot insulated C.S. pipe, size 2" thru 8", Type-S1 (for temp. up to 343°C) Pipe shoe for hot insulated C.S. pipe, size 10" thru 30", Type-S2. (for temp. up to 343°C) Pipe saddle for bare pipe size 14” thru 48” type- S6A Pipe shoe for slope line pipe size 2" thru 6" type-S9A/9B/9C Low support sliding for bare and insulated pipe size 2" thru 36" type-L1 & L1A Low support fixed for bare & insulated pipe size 2" thru 36" type-L3 & L3A. Low support sliding for bare pipe size 3/4" thru’ 36" type-L5 & L5A. Low support sliding for bare and insulated pipe size 2” thru 36” Type-L6 Low support Fixed/Restrained for bare and insulated pipe size 2" thru 36", type-L7 & L7A

0

S-05-01-007

01

0

S-05-01-008

01

0

S-05-01-009

01

0 0

S-05-01-010 S-05-01-011

01 02

0

S-05-01-012

01

0

S-05-01-013

01

0

S-05-01-014

01

0

S-05-01-015

01

0

S-05-01-016

01

0

S-05-01-017

02

0

S-05-01-018

02

0

S-05-01-019

02

0

S-05-01-020

02

0

S-05-01-021

02

0

S-05-01-022

01

0

S-05-01-023

01

0

S-05-01-024

02

0

S-05-01-025

03

Page 5 of 7

26 27 28 29 30 31

32 33 34 35 36 37 38 39 40 41 42 43 44

Restrained Low support for bare and insulated pipe size 2" thru 36", type-L8 & L8A Adjustable low support sliding for pipe size 2" thru 6" typeL10 & L10A Low support sliding & fixed for pipe size 3/4" thru 11/2"typeL15. Low support stanchion for bare & insulated CS/AS/SS pipe type – L16 and L16A Adjustable low support with 4 bolts for pipe size 8" thru 24" type-L17 & L17A. Adjustable low support for bare and insulated pipe size 2" thru 24". type-L18 & L18A Adjustable low support with guide & cross guide for bare and insulated pipe size 2" thru 24" type-L19 & L19A. Pipe clamp for bare pipe size 1/2" thru 24” Type C-1 U-bolt for bare pipe size 1/2" thru 24" type-C4 Dummy pipe support for bare pipe size 2" thru 24" type B-39 Dummy pipe support for insulated pipe size 2" thru 24" type-B40 Pipe support brackets type-B42 Guide support for bare size 1/2" thru 24" type-G1 Guide support for bare size 1/2" thru 24" type-G2 & G2A Cross guide for bare pipe size 2" thru 24" type-G3 Cross guide for bare pipe size 2" thru 24" type-G4. Anchor for bare pipe size 2" thru 24" type-G5. Supporting arrangement for angle & relief valves type-SP2. Typical anti vibration support for control valve-SP3.

0

S-05-01-026

01

0

S-05-01-027

01

0

S-05-01-028

02

0

S-05-01-029

01

0

S-05-01-030

02

0

S-05-01-031

01

0

S-05-01-032

02

0

S-05-01-033

01

0

S-05-01-034

01

0

S-05-01-035

02

0

S-05-01-036

02

0

S-05-01-037

01

0

S-05-01-038

01

0

S-05-01-039

02

0

S-05-01-040

02

0

S-05-01-041

02

0

S-05-01-042

02

0

S-05-01-043

01

0

S-05-01-044

01

Page 6 of 7

LAYOUT DRAWING & PORTACABIN PLAN Layout Sultanpur Dispatch 1 0 Terminal Layout SV-1 (Sultanpur 2 0 Neemrana) 3 Dharuhera CGS & TOP 0 Layout Bhiwadi / Chopanki TOP 4 0 Station 5 Layout Bhiwadi CGS 0 6 Layout SV-2 & Khushkhera CGS 0 Layout SV-3, Sultanpur 7 0 Neemrana 8 Layout Neemrana CGS & RT 0 Layout Hayatpur TOP (for 9 0 Manesar) 10 Layout Manesar CGS 0 11 Layout Hayatpur PRS 0 12 Layout SV-1 (Gurgaon Line) 0 13 Layout Gurgaon Terminal 0 14 Porta-Cabin Layout 0 DATASHEETS – LINEPIPE / PIPING 1 Datasheet of Ball Valve 2 Datasheet of Ball Valve 3 Datasheet of Ball Valve Datasheet of Scraper Launcher / 4 Receiver 5 Datasheet of Pig Signaler 6 Datasheet of IJ Datasheet of Flow Tee (Barred 7 Tee) - 18" X 18" , 600# Datasheet of Flow Tee (Barred 8 Tee) - 18" X 12" , 600# Datasheet of Flow Tee (Barred 9 Tee) - 18" X 8" , 600# Datasheet of Quick Opening End 10 Closure Datasheet of Gas Powered Valve 11 Actuator 12 Datasheet of Plug Valve 13 Datasheet of Plug Valve Data Sheets of Gate Valves of 14 Size below 2”

0001-00-10-01-6002

01

0001-00-10-01-6003

01

0001-00-10-01-6004

01

0001-00-10-01-6005

01

0001-00-10-01-6006 0001-00-10-01-6007

01 01

0001-00-10-01-6008

01

0001-00-10-01-6009

01

0001-00-10-01-6010

01

0001-00-10-01-6011 0001-00-10-01-6012 0001-00-10-01-6013 0001-00-10-01-6014 0001-00-10-01-6015

01 01 01 01 02

0 0 0

0001-01-04-04-BV-001 0001-01-04-04-BV-002 0001-01-04-04-BV-003

01 01 01

0

0001-01-04-04-PL/PR-001

01

0 0

0001-01-04-04-PSG-001 0001-01-04-04-IJ-001

01 01

0

0001-01-04-04-FLT-001

01

0

0001-01-04-04-FLT-002

01

0

0001-01-04-04-FLT-003

01

0

0001-01-04-04-QOEC-001

01

0

0001-01-04-04-GVA-001

04

0 0

0001-01-04-04-PV-001 0001-01-04-04-PV-002

01 01

0

0001-01-05-04-GV-001

03

Page 7 of 7

ENGINEERING DESIGN BASIS (PIPELINE ENGINEERIG) SPUR LINES OF CHAINSA – JHAJJAR PIPELINE

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 1 of 19

Copyright GAIL – All rights reserved

TABLE OF CONTENTS

1.0

INTRODUCTION

2.0

SCOPE

3.0

DESIGN CODES AND STANDARDS

4.0

DESCRIPTION OF FACILITIES

5.0

PIPELINE ROUTE

6.0

DESIGN DATA

7.0

PIPELINE AND ASSOCIATED FACILITIES DESIGN

8.0

OTHER TECHNICAL REQUIREMENTS

ANNEXURE-A

LIST OF CODES AND STANDARDS

ENCLOSURES: 1. Schematic Arrangement for Pipeline Facilities Drawing no. 0001-00-03-01-5003.

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 2 of 19

Copyright GAIL – All rights reserved

1.0

INTRODUCTION M/s GAIL (India) Ltd., proposes to lay following Natural Gas spur Pipelines (from Chainsa- Jhajjar pipeline):Sl.

Pipeline

Tap-off Point

Size(Inch) X Length (Km)

1

Sultanpur Haryana) to Neemrana (Rajasthan)

Tap-off point at Chainage – 70.05 Km in Chainsa-Jhajjar line

18” X 85.28

2

Spur Line to Bhiwadi

Tap-off point at Chainage – 12” X 9 31.6 Km in Sultanpur – Neemrana Line

3

Hayatpur to Manesar

Tap-off point at Chainage – 61.14 Km in Chainsa-Jhajjar line

4

Hayatpur to Gurgaon

Tap-off point at Chainage – 10” X 11 61.14 Km in Chainsa-Jhajjar line

10” X 5.4

These pipelines are to cater the natural gas requirement of consumers at Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar and Khandsa/Gurgaon. The Sultanpur-Neemrana pipeline is proposed to pass through Dharuhera and Khushikhera. The above proposed pipeline shall have laying length as given above and 4 nos. of Sectionalising Valve (SV) stations. The pipeline shall be designed to handle Natural Gas & RLNG. 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.

3.0

DESIGN CODES AND STANDARDS Pipelines and terminal facilities envisaged shall be designed and engineered GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 3 of 19

Copyright GAIL – All rights reserved

primarily in accordance with the provisions of the latest edition of Code ASME B 31.8: Gas Transmission and Distribution Piping Systems and OISD 141: Design and Construction Requirements for Cross Country Hydrocarbon Pipelines. In addition, requirements, as applicable to gas service of following codes/standards shall be complied with: OISD Std. 138

Inspection of Cross Country Pipelines-Onshore

ASME B 31.3

Chemical Plant & Petroleum Refinery Piping

API Std. 1102

Steel Pipeline Crossing Railways & Highways

API Std. 1104

Standard for Welding Pipelines and Related Facilities

ISO 13623

Petroleum & natural gas industries – Pipeline transportation systems

In addition to above, codes and standards listed in Annexure-A of this document shall also be referred. In case of conflict between the requirements of ASME B31.8/OISD 141 and other codes/Standards referred above, requirement of ASME B 31.8/OISD 141 shall govern. In case of conflict between requirements of B31.8/OISD 141 and this document, requirements of this document shall govern. 4.0

DESCRIPTION OF FACILITIES Details of facilities shall be as per P&ID’s, process design basis, data sheets, line schedule etc covered in the process package. The pipeline facilities envisaged as a part of Spur Line of Chainsa-Jhajjar Pipeline are described briefly herein below.

4.1

SULTANPUR – NEEMRANA LINE

4.1.1 Despatch cum Receipt Station at Sultanpur and Neemrana Facilities at Despatch cum Receipt Station at Sultanpur & Neemrana terminals shall consist of Pig launcher cum receiver complete with associated piping including hook-up with existing Chainsa-Jhajjar Pipeline at Chainage 70.50 Km in Sultanpur. Additionally Neemrana terminal shall have filtering, metering and let down skid (CGS). 4.1.2 SV & TOP at SV-1 (Ch. 16.02 Km), SV-3 (Ch. 62.2) Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Sectionalizing Valve in Main line. 4.1.3 TOP & CGS at Dharuhera, Bhiwadi Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Filtering, metering and let down skid with associated piping and Instruments. GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 4 of 19

Copyright GAIL – All rights reserved

4.1.4 SV-2 , TOP and CGS at Khushkhera Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Sectionalizing Valve in Main line. Filtering, metering and let down skid with associated piping and Instruments. 4.1.5 Bhiwadi/ Chopanki TOP for Bhiwadi Tap-off with flow tee and valve all underground. 4.2

HAYATPUR – MANESAR LINE

4.2.1 TOP Hayatpur for Manesar Line Extending the existing Tap-off off with valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline 4.2.2 TOP & CGS at Manesar Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Filtering, metering and let down skid with associated piping and Instruments. 4.3

HAYATPUR – GURGAON LINE

4.3.1 PRS at Hayatpur Extending the existing Tap-off off with PRS/ valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline 4.3.2 SV-1 – Gurgaon Line (Ch. 6.4 Km) Sectionalizing Valve (underground) at Chainage 6.4 Km. 4.3.2 Gurgaon Terminal Station Provision for Insulating Joint at the buried/ above ground transition in the above ground section of pipeline. Tap-off with Valve and Blind as per P&ID. 4.2

Main Pipeline Pipeline facilities are schematically indicated in drawing no. 0001-00-03-01-5003.

5.0 5.1

PIPELINE ROUTE Pipeline Route 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:

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 5 of 19

Copyright GAIL – All rights reserved

SALIENT FEATURES OF RESPECTIVE PIPELINE ROUTE Sultanpur – Spur Line Hayatpur Hayatpur Neemrana to Bhiwadi Manesar Gurgaon Size, OD ( Inch) 18 12 10 10 Length (Km) 85.28 9 5.4 11 Highest elevation Refer Survey Refer Refer Survey Refer Survey Report Survey Report Report above MSL (m) Report Lowest elevation above Refer Survey Refer Refer Survey Refer Survey Report Survey Report Report MSL (m) Report No. of River Crossing , 0 0 0 0 Width > 100 m No. of Road Crossing 3/2 0/2 0/0 1/0 (NH/SH) No. of Railway 3 0 0 0 Crossing No. of Canal Crossing 6 0 0 0 5.2

Terrain Details For Terrain details and Land use pattern refer survey reports prepared by M/s MASCON MSC PVT. Ltd and M/s SKP Projects P. Ltd. attached elsewhere in the bid document.

6.0 6.1

DESIGN DATA Main pipeline shall be designed for conditions as follows: PIPELINE DESIGN PARAMETER Description Value Sultanpur – Neemrana Line 457.2 mm OD Bhiwadi/ Chopanki Tap-off – Bhiwadi Line 323.9 mm OD Hayatpur to Manesar 273.1 mm OD Hayatpur to Gurgaon PRODUCT – Natural Gas/ RLNG Design Pressure (Kg/ Cm2g) 99.93 2 Operating Pressure (Kg/ Cm g) 60-99 0 Maximum Design Temperature, C i. Above Ground Section -29 to 65.0 ii. Under Ground Section -29 to 45.0 Operating Temperature, 0 C 13 - 25 Economic Design Life, Years 35 Corrosion Allowance 0 Hayatpur to Gurgaon – Design Pressure shall be 49 273.1 mm OD 2 Kg/cm g and Design Temp AG/UG (-) 29 to 65 / (-) 29 to 45. Rest other parameter shall be as above.

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 6 of 19

Copyright GAIL – All rights reserved

All terminal facilities (equipment and associated piping) shall be designed for design and operating conditions given in the process package. 7.0

PIPELINE AND ASSOCIATED FACILITIES DESIGN

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.

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 7 of 19

Copyright GAIL – All rights reserved

Location Class

Design Factor

All

Station Piping

Class – 1

River / Stream Crossings  Drilled / Bored/ Inaccessible / Open Cut  Others  HDD Cased/Uncased Crossings or Parallel Encroachments on ROW of Hard Surfaced Roads, Public Streets and Highways Railway Crossing

Class – 2

7.3

Type of Facility

0.5

River / Stream Crossings  Drilled / Bored/ Inaccessible / Open Cut  Others  HDD Cased/Uncased Crossings or Parallel Encroachments on ROW of Hard Surfaced Roads, Public Streets and Highways Railway Crossing

0.6 0.72 0.5 0.6 0.5 0.5 0.6 0.5 0.5 0.5

Class – 3

All

0.5

Class – 4

All

0.4

Station Piping

7.3.1 Station piping to be provided at terminals, intermediate stations, SV stations shall be designed in accordance with OISD 141/ASME B 31.8 and utility piping to be provided at these locations shall be designed in accordance with the provisions of ASME B 31.3. 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. GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 8 of 19

Copyright GAIL – All rights reserved

Sr. No.

LINE SIZE

GRADE

Class - I Class - II

Class - III

Class IV

1

18”(457.2 mm)

6.5

7.9

9.3

11.7

2

12” (323.9 mm)

6.4

6.4

7.9

9.5

3

10” (273.1 mm)

X-70, PSL-2 X-60, PSL-2 X-60, PSL-2

6.4

6.4

6.4

7.8

-

7.4.2 Other Materials All other materials and equipments including scraper traps, flow tees, insulating joints, ball valves, plug valves, globe valves, check valves, pig signallers, flanges and fittings shall be carbon steel suitable for the service conditions and shall be compatible with the line pipe material. 7.5

External/ Internal corrosion coating

7.5.1 Pipeline to be installed below ground shall be protected against external corrosion by a combination of high integrity externally applied coatings and permanent impressed cathodic protection system. Externally applied coating shall be three layer side extruded polyethylene coating. 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. 7.6

Insulating joints 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 GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

PIPELINE ENGINEERING

0001-01-04-03-001

REV-0 Page 9 of 19

Copyright GAIL – All rights reserved

given below or as per the requirements of statutory/local authorities whichever is more stringent. Increased cover shall be provided at critical locations and crossings. Sl.

Location

Minimum Cover (m)

1.0

Industrial, commercial and residential area

1.0

2.0

Rocky terrain

1.0

3.0

Minor water crossing/ canal/ drain/ nala/ waterways

1.5

4.0

HDD crossing of canals (below bed)

2.5

5.0

River crossings for which scour depth is defined (below scour)

1.5

6.0

Other River crossings (Bank width > 50m) (Below Bed)

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

7.0

Other River crossings (Bank width < 50m) (Below Bed)

1.5

8.0

Cased/uncased road crossing

1.2

9.0

Cased railway crossing

1.7

10.0

Drainage, ditches at roads/railway crossings

1.2

11.0 Marshy land/Creek area

1.5

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. 7.8

Marshy Areas / Areas Prone to Flooding Wherever marshy areas/areas prone to flooding are encountered along the pipeline route, pipeline shall be provided with anti buoyancy measures viz. continuous concrete coating/ Geotextile gravel filled bags. Unless specified otherwise in AFC drawings, specific gravity of installation in such areas shall be at least 1.2.

7.9

Pipeline in common ROW The location of new underground pipeline, when running parallel to an existing underground pipeline in same ROU/ROW shall be laid at minimum clear distance of 5.0 m from the existing underground pipeline. This distance may be reduced to 3.0 m after GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 10 of 19

Copyright GAIL – All rights reserved

assessment of construction methodology which do not result in unsafe conditions during construction. 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. 8.0

OTHER TECHNICAL REQUIREMENTS

8.1

Scraper Stations 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. GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

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 GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 12 of 19

Copyright GAIL – All rights reserved

philosophy to be adopted for the project. At locations, where valve stations are combined with CP/Repeater stations, the safe distance and statutory clearance as per standard shall be followed. 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         8.4

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. Welding

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 13 of 19

Copyright GAIL – All rights reserved

Welding shall be carried out in accordance with API 1104, specification for welding and welding charts. Butt welds shall be 100 % radio graphed / automatic UT for automatic welding, as applicable for all pipelines. For gas service all butt welds for process piping shall be 100% radiographed and for utility piping NDT requirements shall be as per specification no. S-05-02-12. 8.5

Hydrostatic Testing After installation, the entire pipeline system shall be hydrotested with inhibited water. The water shall tested, as applicable prior to using for hydrotesting. The minimum hydrostatic pressure in any section shall be as per ASME B 31.8 for gaseous hydrocarbon pipelines. The maximum hydrostatic test pressure at any location of the pipeline shall not exceed the pressure required to produce a hoop stress equal to 95% of SMYS of the pipe material based on minimum wall thickness in the test section. The test duration shall be minimum 24 hours. Hydrostatic testing of terminals shall be carried out separately. Terminals as well as other intermediate facilities shall be tested at 1.4 times the design pressure. The test duration shall be 6 hours. Mainline valves shall be installed after successful completion of hydrotesting.

8.6

Dewatering and swabbing Dewatering, swabbing and pre-commissioning operations shall be carried out after hydrotesting and prior to commissioning of the pipeline as per Project specifications. For gaseous hydrocarbon pipeline the line shall be dried. Swabbing shall be carried out prior to installation of Sectionalizing valves. After swabbing operation the pipeline sections shall be dried as per relevant specification enclosed with the tender.

8.7

Crossings

8.7.1 Water Crossings All water crossing shall be installed by open cut. The requirement of HDD at any water crossing shall be finalized during detailed engineering. Wherever there is an evidence of bank erosion, the banks shall be protected by using gravel and boulders filled embankment mattresses of galvanized iron wire to be laid over the backfilled, compacted and graded banks. 8.7.2 Rail Crossing Pipeline at rail crossings shall be provided with casing pipe. The size of Casing pipe shall be – 609.6 mm O.D. (24”), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW (unless advised otherwise by concerned authorities) and shall be installed by boring/ jacking/ HDD/ ramming. The rail crossing shall comply with the requirements of API 1102 and Indian Railway Authorities. The crossing angle shall be as close to 90º as possible. It should be noted that the extent of casing pipe generally specified by Railways is 14.0 m beyond centerline of the outermost tracks on either side or 0.6 meter beyond the ROU limits of Railways on either side, whichever is more. Carrier pipe shall be electrically insulated from the casing pipe and casing ends shall be sealed using durable, GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 14 of 19

Copyright GAIL – All rights reserved

electrically non-conducting materials. The crossing drawing shall be subject to approval of concerned Railway Authorities prior to implementation. 8.7.3 Road Crossing Road crossings shall comply with the requirements of API 1102 and the requirements of the concerned road authorities. Unless otherwise required by concerned Authorities, casing pipe shall not be used. However at national highway road crossings pipeline shall be provided with casing pipe, which shall extend min. 600 mm beyond Road ROW on either side. The casing pipe shall be installed by trenchless method like ramming/ boring/ jacking/ HDD /Micro Tunelling. Provision of casing at locations other than national highways shall be decided based on type of road crossing and as per requirements of local authorities if necessary. The casing pipe shall be 609.6 mm O.D. (24”), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW. The crossing angle shall be as close to 90º as possible. Casing insulators and end seals shall be provided to ensure electrical isolation of carrier pipe and casing pipe. 8.7.4 Existing Pipeline Crossing The specific requirements of Owner/operator of existing pipeline shall generally be followed. The minimum clearance between the lines shall be 300 mm unless specified otherwise. 8.8

Valves

8.8.1 Application of various types of valves shall be as follows: Valve type

Typical application

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 GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

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: Minimum Bend Radius Pipeline Details 18”, X-70, PSL-2 (thk. 6.5/7.9/9.3 mm) 12”, X-60, (thk. 6.4/7.9/9.5 mm) 10”, X-60, (thk. 6.4/ 7.8 mm)

Hot Formed Cold Field LR Bend Bend Radius Radius R=27 D

R=6D

R=18 D

R=6D

R=18 D

R=6D

8.11 Pig Signallers 8.11.1 Pig signallers shall be installed as a minimum at the following locations at each Launcher/ Receiver: -

On Pig launcher cum receiver

-

One location on the line

8.11.2 Pig signaller shall be bi-directional type with trigger mechanism, suitable for maintenance with pipeline under operating pressure. 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: GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 16 of 19

Copyright GAIL – All rights reserved

1. Line Pipes API 5L API 5L1 API 5LW 2. Valves API 6D API 602 ASTM A694 MSS-SP-6 MSS-SP-25 BS 5351

Specification for Line pipe Recommended Practice for Railroad Transportation of Line pipe Recommended Practice for Transportation of Line pipe on Barges & Marine Vessels Specification for pipeline valves (Steel Gate, Plug, Ball and Check Valves) Compact Steel Gate Valves-Flanged, Threaded, Welding & Extended Body ends. Forgings, Carbon & Alloy steel for Pipe Flanges, Fittings, Valves & parts for High Pressure Transmission Service. Finishes for Contact Faces of connecting End Flanges of Ferrous Valves and Fittings. Standard Marking System for Valves, Fittings & Unions 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 Flanges Forgings, Carbon Steel for Piping Components

ANSI 16.20 ASTM A105 ASTM A193 API 601

Carbon & Alloy Steel Bolts & Studs for High Temperature Service 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 ASTM A234

Butt Welding Ends

ASTM A694 MSS-SP-75 GAIL (INDIA) LTD NEW DELHI

Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Forgings, Carbon & Alloy Steel for Pipe Flanges, Fittings, Valves & Parts for High Pressure Transmission Service. Specification for High Test Wrought Butt Welding Fittings ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

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. Pipe Bending Methods, Tolerances, Processes & Material Requirements

PFI-ES-24 4. Testing & Welding ANSI/AWS D1.1 API 1104 AWS A3.0

Structural Steel Welding Standard for Welding Pipelines and Related Facilities Welding Terms and Definitions

AWS A5.1 AWS A5.5

Welding Electrodes Specification for Low Alloy Steel Covered Arc Welding Electrodes

ASTM E165 ASTM A370

Liquid Dye Penetrant Inspection of Pipeline Welds

ASTM E18

Standard Methods and Definitions for Mechanical Testing of Steel Products. Standard Hardness Test for Metals

ASTM E23

Standard for Impact Test for Metals

ASTM E84 ASTM E92

Standard Test Method for Micro-hardness of Metals Standard Test Method for Vickers Hardness of Metallic Materials Standard Test Method Indentation Hardness for Metallic Materials by Portable Hardness Testers

ASTM E110 ASTM E709 MSS-SP-53 MSS-SP-54 MSS-SP-55

Standard Guides for Magnetic Particle Examination Quality Standard for Steel Casting & ForgingMagnetic Particle Method Quality Standard for Steel Casting & ForgingRadiographic Examination Quality Standard for Steel Castings & ForgingsVisual Method.

5. Surface Preparation, Painting and Coating SIS-05-59 SSPC-SP-01

Pictorial Surface Preparation Standards for Painting Steel Surfaces Solvent Cleaning

SSPC-SP-03

Power Tool Cleaning

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 18 of 19

Copyright GAIL – All rights reserved

SSPC-SP-05

Joint Surface Preparation Standard: White Metal Blast Cleaning

SSPC-SP10

Structural Steel Painting Council – Joint Surface

NACE No.2

Preparation Standard - Near-White Metal Blast Cleaning

SSPC-PA-02

Measurement of Dry Paint Thickness and Magnetic Gauges

ASTM E12 ASTM-G6

Measurement of Pipeline Dry Film Coating Thickness Abrasion Resistance of Pipeline Coating

ASTM G8

Cathodic Disbonding of Pipeline Coatings

NACE-RP-0274

High Voltage Electrical Inspection of Pipeline Coatings Prior to Installation

IEC 454 – 2

Specification for Pressure-Sensitive Electrical Purposes

Adhesive

Tapes

for

CSA Z245.20-02 External Fusion Bond Epoxy Coating for Steel Pipe 6. Safety Systems IP Model Code of Safe Practice in the Petroleum Industry parts 3, 6 and 9.

GAIL (INDIA) LTD NEW DELHI

ENGINEERING DESIGN BASIS

SPECIFICATION

REV-0

PIPELINE ENGINEERING

0001-01-04-03-001

Page 19 of 19

Copyright GAIL – All rights reserved

PIPING MATERIAL SPECIFICATION

SPUR LINES OF CHAINSA – JHAJJAR PIPELINE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 1 of 68

CONTENTS SL NO.

DESCRIPTION

1.0

SCOPE

2.0

CODES AND STANDARDS

3.0

MATERIAL SPECIFICATIONS

4.0

CLASS DESIGNATION CODES

5.0

PIPELINE

6.0

PIPING

7.0

FITTINGS

8.0

BENDS

9.0

FLANGES

10.0

GASKETS

11.0

BOLTING

12.0

THREAD SERALANT

13.0

VALVES

14.0

QUICK OPENING END CLOSURE

15.0

HYDROTESTING VENT AND DRAINS

16.0

PIPELINE SPECIALITY ITEMS

TABLE - 1

PIPE WALL THICKNESS DETAILS FOR MAINLINE SPUR LINE

TABLE - 2

PRESSURE/TEMP & OTHERS DESIGN CONDITIONS FOR VARIOUS PIPING CLASSES

ANNEXUREMATERIAL SPECIFICATIONS FOR PIPING CLASSES A,B,C,D,E,F,G,H,I ANNEXURE-1 LIST OF ATTACHMENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 2 of 68

1.0

SCOPE

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.

2.0

CODES AND STANDARDS

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

(ii)

ASME B31.3

-

Chemical Plant and Petroleum Refinery Piping

(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.

3.0

MATERIAL SPECIFICATIONS 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.

4.0

CLASS DESIGNATION CODE 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: First letter indicates ASME Class rating e.g. PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 3 of 68

A – Class 150 B – Class 300 D – Class 600 E – Class 900 The middle number indicates differences in the specifications within the same class rating and material.

The last letter indicates type of material. E.g. A – Carbon steel. 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-SP97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturer’s standard.

7.8

Fittings thickness tolerances shall match pipe thickness tolerance.

8.0

BENDS PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 4 of 68

8.1

Unless otherwise specified for process piping, elbow of radius R 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.

8.3

Miters shall not be used.

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.

9.8

Butt welding ends of WN flanges shall conform to ASME B 16.25.

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.

10.2

Spiral wound gasket shall be self-aligning type.

11.0

BOLTING & THREADS

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.

11.3

Threads for nuts shall be as per ASME B 1.1 Nuts for stud bolts dia ¼“ to 1”

:

1.5 D shall only be used.

UNC-2B

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

=

SPECIFICATION 0001-01-05-02-001

REV-0 Page 5 of 68

Nuts for stud bolts dia 1⅛ %” to 3¼ 11.4

:

8UN-2B

Threads for stud bolts shall be as per ASME B 1.1, as follows: Stud bolts dia ¼“ to 1”

:

UNC-2A

Stud bolts dia 1⅛ %” to 3¼

:

8UN-2A

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.

12.0

THREAD SEALANT

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. Flanged/ Socket Welded end valves (1½” and below) Design STD. for Process lines Gate Valves Globe Valves Ball Valves Plug Valves

: : : :

API 602 BS 5352 BS 5351 BS 5353

Flanged/ Butt Welded end valves (2” and above) Design STD. for Process Lines Gate Valves Globe Valves Check Valves

: : :

API 6D BS 1873 API 6D

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 6 of 68

Ball Valves Plug Valves 13.8

: :

API 6D API 6D

All manual operated valves shall be provided with wrench I hand wheel or gear operator as specified here in below.

13.8.1 Gate Valves 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

13.8.2 Globe Valves For ANSI class 150, 300, 600 and 900 - Hand Wheel operated for all size 13.8.3 Ball valves & Plug Valves For all ANSI class

:

Wrench operated for size ≤ 4” NB. Gear operated for size ≥ 6” NB.

13.8.4 Gas Actuated Valves 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. 14.0

QUICK OPENING END CLOSURE 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.

15.0

HYDROTESTING VENTS AND DRAINS 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.

16.0

PIPELINE SPECIATLITY ITEMS Pipeline specialty items viz, scraper traps, Barred tees, insulating joints, LR bends etc. shall be as per specifications attached elsewhere.

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 7 of 68

GAIL (INDIA) LTD NEW DELHI

12 10 10

Bhiwadi/Chopanki TOP – Bhiwadi Spur Line

Spur line Hayatpur - Manesar

Spur Line Hayatpur - Gurgaon

3.

3.

18

X – 60, PSL-2

X – 60, PSL-2

X – 60, PSL-2

X – 70, PSL-2

SEAMLESS ,EW

SEAMLESS ,EW

SEAMLESS ,EW

LSAW, HSAW, SEAMLESS, EW

6.4

6.4

6.4

6.5

METHOD OF MANUFACTURE

Sultanpur – Nimrana Pipe line

MATERIAL (API 5L) Class –I

TPIPE DIA (INCH)

LINE PIPE

SECTION

2.

1.

Sl. No.

6.4

6.4

6.4

7.9

Class – II

6.4

6.4

7.9

9.3

Class – III

W.T. (mm)

6.4

7.8

9.5

11.7

Class IV

TABLE -1

PIPING MATERIAL SPECIFICATION

SPECIFICATION

0001-01-05-02-001

REV-0 Page 8 of 68

TABLE – 2 Design Condition Pressure Temp. (Kg/cm2 ) (0 C) 99.93 65

Class

Service

D1A

Hydrocarbon Gas

B1A

Hydrocarbon Gas

49.0

65

1.5

A1A

Hydrocarbon Gas

19

65

1.5

A3A

Utilities

10.5

65

1.5

J2A

Potable Water

10.5

65

0

A93A

Fire Water

18.9

65

1.5

C.A. (mm)

Pipe Material

Design Code

1.5

API 5L X – 52/ ASTM A 106 GRB / Gr.B (Charpy) / Gr. B PSL2 as applicable ASTM A 106 GR- B / Gr.B (Charpy) / Gr. B PSL2 as applicable ASTM A 106 GR- B / Gr.B (Charpy) / Gr. B PSL2 as applicable IS-1239 (BLACK) IS-1239 (Galv) IS-1239 (Black)/ IS-3589 GR 410 as applicable

ASME B 31.8 / OISD – 141

ASME B 31.8 / OISD – 141/ 226

ASME B 31.8 / OISD – 141 / 226

ASME B 31.3 ASME B 31.3 ASME B 31.3

CORROSION ALLOWANCE : Above mentioned corrosion allowance is only for station piping. No corrosion allowance is considered in linepipe.

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 9 of 68

ANNEXURE A PIPING MATERIAL SPECIFICATION (A1A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 10 of 68

PIPING CLASS

:

A1A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

SERVICE : NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AMMONIA, STEAM & GAS CONDENSATE (NON- IBR), UTILITIES (WATER, INST, AIR, NITROGEN, CARBON DIOXIDE) AND LUBE OIL BEFORE THE FILTER. 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: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 226.

4.

CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES.

5. 6. 7.

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. FOR VALVES, REFER RESPECTIVE VALVE DATA SHEETS. FOR HANDLE PROJECTION REFER STD. DRG-S-05-01-007. SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS

SIZE ALL

DESCRIPTION FLANGED TO BE KEPT MINIMUM

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD.S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD.S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD – S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD.S-05-01-004

TEMP. CONN

1.5”

PRESS. CONN

0.75”

FLANGED, INSTALLATION AS PER GAIL STD – S-05-01-005. SW NIPPLE WITH GATE VALVE TO SPEC AS PER

DRAINS

VENTS

STD.S-05-01-006

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 11 of 68

T

T

T

W

W

W S

W S

T T T

S S S

S S S

S S S

S S S

S S S

S S S

5.000

W S

4.000

T S

3.500

T S

3.000

T T

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

BRANCH PIPE (SIZE IN INCHES)

T

10.00

T

8.000

T

6.000

T

T

2.500

1.000

T T T

2.000

0.750

T

T T

1.500

T T T 1.250

T

T T

0.500

BRANCH PIPE (SIZE IN INCHES)

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

RUN PIPE (SIZES IN INCH) – A1A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 12 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTMA106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

03.000

03.000

STD

B 36.10

ASTMA106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

04.000

04.000

STD

B 36.10

ASTMA106 GR.B (CHARPY)

BE, SEAMLESS

PIPE

06.000

06.000

STD

B 36.10

ASTMA106 GR.B (CHARPY)

BE, 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

NIPPLE

00.500

00.750

M

B 36.10

ASTMA 106 GR.B

PBE, SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTMA 106 GR.B

PBE, SEAMLESS

FLNG.WN

00.500

01.500

M

B-16.5

ASTM A 105

150, RF/125AARH

FLNG.WN

02.000

24.000

M

B-16.5

ASTM A 105 (CHARPY)

150, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

150, RF/125AARH

PLNG.BLIND

02.000

24.000

B-16.5

ASTM A105 (CHARPY}

150, RF/125AARH

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

150, RF/125AARH

Item Type

Pipe Group (A1A)

Flange Group (A1A)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 13 of 68

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

150, RF/125AARH

SPCR &BLIND

10.000

24.000

B-16.48

ASTM A105 (CHARPY)

150, RF/125AARH

ELBOW.90

00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

24.000

B-16.9

ASTM A 234,GR. WPB (CHARPY)

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTMA 105

SW, 3000

ELBOW.45

02.000

24.000

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

24.000

B-16.9

ASTM A234,GR.WPB (CHARPY)

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTMA 105

SW, 3000

T.RED

02.000

24.000

M, M

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

REDUC.CONC

02.000

24.000

M,M

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

REDUC.ECC

02.000

24.000

M,M

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

00.750

B-16.11

ASTMA 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTMA 105

SCRF, 3000

CAP

02.000

24.000

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

Fitting Group (A1A)

M

M

M

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 14 of 68

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

SOCKOLET

00.500

0.750

MSSSP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 105

SW, 3000

WELDOLET

02.000

10.000

MSSSP97

ASTMA 105 (CHARPY)

BW

VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIM-STELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIM-STELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTMA 105,TRIM-STELLITED

SW,800, 3000, B16.11

00.500

24.000

B18.2

BOLT: 193 GR.B7,NUT: A194 GR. 2H

24.000

B16.20ANSI B 16.5

SP,WND, SS316+CAF

O’let Group (A1A)

M, XXS

Valves Group (A1A)

Bolt Group (A1A) BOLT.STUD

Gasket Group (A1A) GASKET

00.500

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPIRAL, 150

SPECIFICATION 0001-01-05-02-001

REV-0 Page 15 of 68

ANNEXURE B PIPING MATERIAL SPECIFICATION (A3A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 16 of 68

PIPING CLASS

:

A3A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

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.

2.

NDT REQUIREMENT AS PER GAIL STANDARD S-05-02-012

3. FOR VALVES REFER VALVE DATA SHEET SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS

SIZE ALL

DESCRIPTION FLANGED TO BE KEPT MINIMUM

1.5” & BELOW

SW COUPLING 3000 #

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD.S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”, S-05-01-004

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.

DRAINS

VENTS

S-05-01-006

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 17 of 68

P

T

P

P

H H H

H H H

H H H

H H H

BRANCH PIPE (SIZE IN INCHES)

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

6.000

T T T

5.000

P H

4.000

P H

3.500

P H

3.000

T T

2.500

T

2.000

1.000

T

1.500

T T T 1.250

T

T T 0.750

T

0.500

BRANCH PIPE (SIZE IN INCHES)

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

(A3A)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 18 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS

T W I X L

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

PIPE

00.500

1.50

HVY

PIPE

02.000

06.000

NIPPLE

00.500

Item Type

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Material

Description

IS-1239I

IS-1239 (BLACK)

PE, C. WELDED

HVY

IS-1239I

IS-1239 (BLACK)

PE, C. WELDED

01.50

HVY

IS-1239I

IS-1239 (BLACK)

PE, C. WELDED

M

B-16.5

ASTM A 105

150, RF/125AARH

Pipe Group (A3A)

Flange Group (A3A) FLNG.SW

00.500

01.500

FLNG.SO

02.000

06.000

B-16.5

ASTM A 105 (CHARPY)

150, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

150, RF/125AARH

FLNG.BLIND

2.00

6.00

B-16.5

ASTM A105 (CHARPY}

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

150, RF/125AARH 150, RF/125AARH

FLNG.FIG8

02.000

06.000

B-16.5

ASTM A105 (CHARPY)

150, RF/125AARH

B-16.11

ASTM A 105

SW,3000

B-16.9

ASTM A 234 GR. WPB (CHARPY)

BW, 1.5D

B-16.11

ASTM A 105

SW, 3000

B-16.9

ASTM A 234 GR. WPB (CHARPY)

BW, 1.5D

B 16.11

ASTM A 105

SW, 3000

Fitting Group (A3A) ELBOW.90

00.500

01.500

ELBOW.90

02.00

06.00

ELBOW.45

00.500

01.50

ELBOW.45

02.000

06.000

T.EQUAL

00.500

01.50

STD

STD

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 19 of 68

T.EQUAL

02.00

06.00

T.RED

00.500

01.500

T.RED

02.000

06.00

REDUC.CONC

02.000

REDUC.ECC

STD

B 16.11

ASTM A 234 GR. WPB (CHARPY)

BW

B-16.11

ASTM A 105

SW, 3000

STD

B-16.9

ASTM A 234 GR. WPB (CHARPY)

BW

06.000

STD,STD

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

02.000

06.000

STD,STD

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

SWAGE.CONC

00.500

03.000

STD,STD

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

STD,STD

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

01.50

B-16.11

ASTMA 105

SCRF, 3000

CAP

02.000

06.00

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

CPLNG.FULL

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

CPLNG.RED

00.500

01.50

B-16.11

ASTM A 105

SW, 3000

UNION

0.50

01.500

BS-3799

ASTM A 105

SW, 3000

STD

Valves Group (A3A) VLV.GATE

00.250

01.500

API-602

BODY-ASTM A 105, TRIM-STELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GATE

02.00

24.00

API-600

BODY-ASTM A 216, WCB, TRIMSTELLITED, STEM13%CR. STEEL

FLGD, 150, B 16.5, RF/125AARH

VLV.GLOBE

00.25

01.500

BS-5352

BODY-ASTM A 105,TRIM-STELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.GLOBE

02.00

16.00

BS-1873

BODY-ASTM A 216, WCB, TRIMSTELLITED, STEM13%CR. STEEL

FLGD, 150, B 16.5, RF/125AARH

VLV.CHECK

00.250

01.500

BS-5352

BODY-ASTMA 105,TRIM-STELLITED

SW,800, 3000, B16.11

VLV.CHECK

02.00

24.00

BS 1868

BODY-ASTM A 216, GR. WCB, TRIM 13% CR. SREEEL

FLGD, 150, B 16.5, RF/125AARH

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 20 of 68

VLV.BALL

00.500

16.00

BS-5351

BODY-ASTM A 105,A 216 GR. WCB TRIMBODY SEAT - RPTFE

FLGD, 150, , B 16.5, RF/125AARH

VLV.BTRFLY

03.500

24.00

BS-5155

BODY-ASTM A 216 GR., WCB, TRIM- 13% CR. STEEL

WAFL, 150, B16.5 WAF/125AARH

00.500

6.000

B18.2

BOLT: A 307, GR. B, NUT: A 563 GR.B

6.000

B16.21ANSI B 16.5

IS-2712- GR.-W/3

RING, 150, 2 MM

Bolt Group (A3A) BOLT.STUD

Gasket Group (A3A) GASKET

00.500

TRAP/ STRAINER GROUP (A3A) TRP

00.500

1.50

MANF’S STD

B:A105, T:13%CR, S:SS304

FLGD, THRMDNMC, 150, RF/125AARH

TRP

01.500

6.000

MANUF STD

B:A285GR.C; INT: SS304

CONETYPE, 150, FF/125 AARH

TRP

00.500

1.500

MANUF STD

B:A105; INT: SS304

SW, Y-TYPE, 800

TRP

02.00

6.000

MANUF STD

B:A234GR. WPB; INT: SS304

BW, T - TYPE

M

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 21 of 68

ANNEXURE C PIPING MATERIAL SPECIFICATION (B1A - CLASS 300#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 22 of 68

PIPING CLASS

:

(B1A), 300 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

SERVICE NON CORROSIVE PROCESS- FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, 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: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4.

FLANGES OF SIZE 22” SHALL BE AS PER MSS-SP-44.

5.

CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES.

6.

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.

7.

FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

SPECIAL NOTES ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL

FLANGED, TO BE KEPT MINIMUM

PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD.S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”; GAIL STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”. S-05-01-004

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S05-01-006

DRAINS VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 23 of 68

72

70

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

T

20

T

T

18

T

T

T

16

T

T

T

T

14

T

T

T

T

T

12

18 16 14 12 10 8.0 6.0

T

T

T

T

T

T

T

10

T

T

T

T

T

T

T

8.0

T

T

T

T

T

W

W

5.0 T

T

T

T

W

W

W

W

W

3.5

4.0 3.5

3.0

T

T

T

W

W

W

W

W

W

W

2.5

3.0 2.5

2.0 1.5

T

T

T

T

W

W

W

W

W

W

W

W

T

S

S

S

S

S

S

S

S

S

S

2.0 1.5

S

S

S

S

S

S

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

S

S

S

0.5

6.000

8.000

10.000

12.000

14.000

16.000

18.000

20.000

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

S

2.500

S

T

2.000

T

T

1.500

1.0

1.250

T T

1.000

1.25

0.500 0.750

1.25

0.5

6.0 5.0

4.0

0.75

BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)

72

1.0

(B1A)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 24 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTMA 106 GR.B

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTMA106 GR.B (CHARPY)

BE, 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

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

Flange Group (B1A) FLNG.SW 00.500

01.500

M

B-16.5

ASTM A 105

300, RF/125AARH

FLNG.WN

02.000

16.000

M

B-16.5

ASTM A 105 (CHARPY)

300, RF/125AARH

FLNG.WN

18.000

20.000

M

B-16.5

ASTM A 105 (CHARPY)

300, RF/125AARH

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

300, RF/125AARH

FLNG.BLIND

02.000

20.000

B-16.5

ASTM A105 (CHARPY}

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

300, RF/125AARH 300, RF/125AARH

Item Type Pipe Group (B1A)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 25 of 68

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

10.000

20.000

B-16.48

ASTM A105 (CHARPY)

Fitting Group(B1A) ELBOW.90 00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

16.000

M

B-16.9

ASTM A 234,GR. WPB CHARPY)

BW, 1.5D

ELBOW.90

18.000

20.000

M

B- 16.9

ASTM A 234,GR. WPB CHARPY)

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

16.000

M

B-16.9

ASTM A234, GR. WPB CHARPY)

BW, 1.5D

ELBOW.45

18.000

20.000

M

B 16.9

ASTM A234, GR. WPB CHARPY)

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

16.000

M

B-16.9

ASTM A234,GR.WPB (CHARPY)

BW

T.EQUAL

18.000

20.000

M

B – 16.9

ASTM A234,GR.WPB (CHARPY)

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

T.RED

02.000

16.000

M, M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

T.RED

18.000

20.000

M, M

B – 16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.CONC

02.000

16.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.CONC

18.000

26.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.ECC

02.000

16.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.ECC

18.000

20.000

M,M

B – 16.9

ASTM A234,GR. WPB(CHARPY)

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

300, RF/125AARH 300, RF/125AARH

SPECIFICATION 0001-01-05-02-001

REV-0 Page 26 of 68

CAP

00.500

00.750

B-16.11

ASTM A 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

16.000

M

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

CAP

18.000

20.000

M

B – 16.9

ASTM A234,GR. WPB (CHARPY)

BW

PLUG

00.500

00.750

B 16.11

ASTM A 105

SCRM, 6000

PLUG

01.000

01.500

B 16.11

ASTM A 105

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

O’ let group(B1A) SOCKOLET 00.500

0.750

MSS-SP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSS-SP97

ASTM A 105

SW, 3000

WELDOLET

02.000

10.000

MSS-SP97

ASTMA 105 (CHARPY)

BW

M, XXS

Valves Group (B1A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GATE

02.000

20.000

API-6D

BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% CR. STEEL

FLGD, 300, B16.5, RF/ 125 AARH

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.GLOBE

02.000

20.000

BS-1873

BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% CR. STEEL

FLGD, 300, B16.5, RF/ 125 AARH

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTMA 105,TRIM-STELLITED

SW,800, 3000, B16.11

VLV.CHECK

2.000

20.000

API -6D

BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13%

FLGD, 300, B16.5, RF/ 125

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 27 of 68

CR. STEEL

AARH

VLV.BALL

00.500

01.500

BS-5351

BODY-ASTM A 105,TRIMSEAT RPTFE

FLGD, 300, B16.5, RF/ 125 AARH

VLV.BALL

02.000

20.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003” ENP/ AISI 410

FLGD, 300, B16.5, RF/ 125 AARH

VLV.BALL

02.000

02.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003” ENP/ AISI 410

BW, 300, B16.25, RF/ 125 AARH

VLV.PLUG

00.500

01.500

BS-5353

BODY-ASTM A 105, PLUG-A 105 +0.003” ENP

SW,800 3000, B16.11

VLV.PLUG

02.000

20.000

API-6D

BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003” ENP

FLGD, 300, B16.5, RF/ 125 AARH

Bolt Group(B1A) BOLT.STUD 00.500

26.000

B18.2

BOLT: 193 GR.B7,NUT: A194 GR. 2H

Gasket Group (B1A) GASKET 00.500

20.000

B16.20ANSI B 16.5

SP,WND, SS316+CAF

SPIRAL, 300

GASKET

20.000

B16.20ANSIB 16.5

SP,WND, SS316+CAF

SPIRAL, 300

26.000

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 28 of 68

ANNEXURE D

PIPING MATERIAL SPECIFICATION (D1A - CLASS 600#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 29 of 68

PIPING CLASS

:

D1A, 600 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

NON IBR

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

SERVICE - REGASIFIED LNG (R-LNG) / Natural Gas NOTES 1.

ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.

2.

WALL THICKNESS OF LINEPIPE (MAIN PIPELINE) USED SHALL BE AS PER TABLE – 1 ENCLOSED.

3.

BALL VALVE TO BE USED IN MAIN LINE SHALL HAVE BUTT WELDED ENDS.

4.

MAINLINE WELDING AND NDT REQUIREMENTS OF WELDS SHALL AS PER SPECIFICATION – 0001-01-04-02-001.

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.

7.

NDT OF WELDS EXCLUDING MAINLINE SHALL BE AS FOLLOWS: RADIOGRAPHY MPI

: :

ALL BUTT WELDS SOCKET WELDS

-

100% 100%

ALL OTHER REQUIREMENT SHALL BE AS PER S-05-02-012 8.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141

9.

FLANGES OF SIZE 22” SHALL BE AS PER MSS-SP-44.

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 30 of 68

14. SPECIAL NOTES - D1A ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS PIPE JOINTS

ALL 1.5” & BELOW

FLANGED, TO BE KEPT MINIMUM SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD.S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”. REFER STD. S-05-01-003

TEMP. CONN

1.5”

PRESS. CONN

0.75”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS

VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 31 of 68

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

T 30

28

28

26 24

T

22 20

T

18 16

T

14 12 10

T

T 26

T

T 24

T

T

T

T 22

T

T

T

T 20

T

T

T

T

T

T 18

T

T

T

T

T

T 16

T

T

T

T

T

T

T

T 14

T

T

T

T

T

T

T

T

T 12

T

T

T

T

T

T

T

T

W

T 10

T

T

T

T

T

T

T

W

W

W

W 8.0

T

T

T

T

T

T

W

W

W

W

W

W 6.0

T

T

T

T

W

W

W

W

W

W

W

W

W 4.0

T

T

T

W

W

W

W

W

W

W

W

W

W

W 3.0

T

T

T

W

W

W

W

W

W

W

W

W

W

W

W 2.0

T

S

S

S

S

S

S

S

S

S

S

S

S

S

S

8.0 6.0 5.0

5.0

4.0 3.5

3.5

3.0 2.5

2.5

2.0 1.5

T

1.5

S

S

S

S

S

S

S

S

S

1.0

S

S

S

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

S

S

S

S

S

S

S

0.5

2.000

6.000

8.000

10.000

12.000

14.000

16.000

18.000

20.000

22.000

24.000

26.000

30.000

S

S

28.000

S

S

5.000

S

S

4.000

S

S

3.500

S

T

3.000

T

T

2.500

T

T

0.75

1.250

1.0

0.750

T T

1.500

1.25

1.000

1.25

0.5

BRANCH PIPE (SIZE IN INCHES)

72

70

0.500

BRANCH PIPE (SIZE IN INCHES)

72

RUN PIPE (SIZES IN INCH) – D1A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 32 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

PIPE

00.500

00.750

S160

B 36.10

ASTM A 106 GR.B

PE, SEAMLESS

PIPE

01.000

01.500

XS

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

14.000

14.000

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

PIPE

30.00

30.00

2

API 5L

API 5L GR.X-52 PSL2

BE, SAW

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 106 GR.B

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 106 GR.B

PBE, SEAMLESS

Item Type Pipe Group (D1A)

Flange Group (D1A) FLNG.SW

00.500

01.500

M

B-16.5

ASTM A 105

600, RF/125AARH

FLNG.WN

02.000

8.000

M

B-16.5

ASTM A 105 (CHARPY)

600, RF/125AARH

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 33 of 68

FLNG.BLIND

00.500

01.500

B-16.5

ASTM A 105

600, RF/125AARH

FLNG.BLIND

02.000

24.000

B-16.5

ASTM A105 (CHARPY}

FLNG.BLIND

26.000

30.000

B16.47A

ASTM A105 (CHARPY}

FLNG.FIG8

00.500

01.500

B-16.48

ASTM A 105

600, RF/125AARH 600, RF/125AARH 600, RF/125AARH

FLNG.FIG8

02.000

08.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

10.000

24.000

B-16.48

ASTM A105 (CHARPY)

SPCR &BLIND

26.000

30.000

MNF’S STD

ASTM A516 GR.70 (CHARPY)

600, RF/125AARH 600, RF/125AARH 600, RF/125AARH

Fitting Group (D1A) ELBOW.90

00.500

0..750

B-16.11

ASTM A 105

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.90

02.000

8.000

M

B-16.9

ASTM A 234,GR. WPB (CHARPY)

BW, 1.5D

ELBOW.90

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

ELBOW.45

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

ELBOW.45

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

8.000

M

B-16.9

ASTM A234, GR. WPB (CHARPY)

BW, 1.5D

ELBOW.45

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

PIPE BEND

18.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 105

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

8.000

M

B-16.9

ASTM A234,GR.WPB (CHARPY)

BW

T.EQUAL

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

T.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

T.RED

02.000

8.000

M, M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

T.RED

10.000

30.000

M, M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

REDUC.CONC

02.000

8.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.CONC

10.000

30.000

M,M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

REDUC.ECC

02.000

8.000

M,M

B-16.9

ASTM A234,GR. WPB(CHARPY)

BW

REDUC.ECC

10.000

30.000

M,M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 34 of 68

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (CHARPY)

PBE

CAP

00.500

00.750

B-16.11

ASTM A 105

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

8.000

M

B-16.9

ASTM A234,GR. WPB (CHARPY)

BW

CAP

10.000

30.000

M

MSS-SP75

MSS-SP75 GR.WPHY-52

BW

PLUG

00.500

00.750

B 16.11

ASTM A 105

SCRM, 6000

PLUG

01.000

01.500

B 16.11

ASTM A 105

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 105

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 105

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 105

SW, 3000

SOCKOLET

00.500

0.750

MSS-SP97

ASTM A 105

SW, 6000

SOCKOLET

01.000

01.500

MSS-SP97

ASTM A 105

SW, 3000

WELDOLET

02.000

16.000

M, XXS

MSS-SP97

ASTMA 105 (CHARPY)

BW

WELDOLET

18.000

20.000

M, M

MSS-SP97

ASTMA 694 GR. F-52 (CHARPY)

BW

O’ let group (D1A)

Valves Group (D1A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR. STEEL

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTMA 105,TRIM-STELLITED

SW,800, 3000, B16.11

VLV.BALL

00.500

01.500

BS-5351

BODY-ASTM A 105,TRIM-SEAT RPTFE

FLGD, 600, B16.5, RF/ 125 AARH

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 35 of 68

VLV.BALL

02.000

24.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003” ENP/ AISI 410

FLGD, 600, B16.5, RF/ 125 AARH

VLV.BALL

26.000

30.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003” ENP/ AISI 410

BW, 600, B16.25, RF/ 125 AARH

VLV.BALL

02.000

30.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003” ENP/ AISI 410

BW, 600, B16.25, RF/ 125 AARH

VLV.PLUG

00.500

01.500

BS-5353

BODY-ASTM A 105, PLUG-A 105 +0.003” ENP

SW, 800 3000, B16.11

VLV.PLUG

02.000

24.000

API-6D

BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003” ENP

FLGD, 600, B16.5, RF/ 125 AARH

VLV.PLUG

02.000

24.000

API-6D

BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003” ENP

BW, 600, B-16.5, RF/ 125 AARH

00.500

30.000

B18.2

BOLT: 193 GR.B7,NUT: A194 GR. 2H

Bolt Group(D1A) BOLT.STUD

Gasket Group(D1A) GASKET

00.500

24.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

SPIRAL, 600

GASKET

26.000

30.000

B16.20ANSI B16.47A

SP,WND, SS316+CAF

SPIRAL, 600

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 36 of 68

ANNEXURE E

PIPING MATERIAL SPECIFICATION (A4A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 37 of 68

PIPING CLASS

:

A4A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

LOW TEMPERATURE SERVICE

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

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: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4.

IMPACT TESTING IS REQUIRED

5.

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.

6.

FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007 SPECIAL NOTES

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL

FLANGED, TO BE KEPT MINIMUM

PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”.REFER STD. S-05-01-003

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 38 of 68

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18

18

16

16

14

T

14

T

T

12

T

T

T

10

T

T

T

T

8.0

T

T

T

T

12 10 8.0 6.0

T

5.0 T

T

T

T

W

W

3.5

4.0 3.5

3.0

T

T

T

W

W

W

W

2.5

3.0 2.5

2.0 1.5

T

T

T

T

W

W

W

W

W

T

S

S

S

S

S

S

S

2.0 1.5

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

0.5

8.000

10.000

12.000

14.000

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

S

2.500

S

T

2.000

T

T

1.500

1.0

1.250

T T

6.000

1.25

1.000

1.25

0.5

6.0 5.0

4.0

0.75

BRANCH PIPE (SIZE IN INCHES)

72

70

0.500 0.750

BRANCH PIPE (SIZE IN INCHES)

72

1.0

RUN PIPE (SIZES IN INCH) A4A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 39 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Upper Lower Size Size (Inch) (Inch)

Item Type

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Sch./ Thk

Dim. STD

Material

Description

Pipe Group (A4A) PIPE

00.500

00.750

S160

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

03.000

14.000

STD

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 333 GR.6

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 333 GR.6

PBE, SEAMLESS

Flange Group (A4A) FLNG. WN 00.500

14.000

M

B-16.5

ASTM A 350 GR. LF2

150, RF/125 AARH

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

ASMEB16.48

ASTM A 350 GR. LF2

150, FF/125 AARH

SPCR &BLIND

10.000

14.000

ASMEB16.48

ASTM A 350 GR. LF2

150, FF/125 AARH

Fitting Group (A4A) ELBOW.90

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.90

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.45

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.45

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.45

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 350 GR.LF2

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 350 GR.LF2

SW, 3000

T.EQUAL

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW

T.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

M

M

M

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 40 of 68

T.RED

02.000

14.000

M, M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.CONC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.ECC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 350 GR.LF2

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 350 GR.LF2

PBE

CAP

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SCRF, 6000

CAP

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SCRF, 3000

CAP

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O’ let group(A4A) SOCKOLET 00.500

0.750

MSS-SP97

ASTM A 350 GR.LF2

SW, 6000

SOCKOLET

01.000

01.500

MSS-SP97

ASTM A 350 GR.LF2

SW, 3000

WELDOLET

02.000

10.000

MSS-SP97

ASTM A 350 GR.LF2

BW

M

M, XXS

Valves Group (A4A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS-304

SW,800, 3000,B16.11

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B16.11

VLV.CHECK

00.500

01.500

BS-5352

BODY-ASTM A 350, GR.LF2, TRIM-STELLITED

SW,800, 3000, B16.11

00.500

14.000

B18.2

BOLT: A 320 GR.L7, NUT:A194 GR.4

Bolt Group (A4A) BOLT.STUD

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 41 of 68

Gasket Group (A4A) GASKET

00.500

14.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

SPIRAL, 150

REV-0 Page 42 of 68

ANNEXURE F

PIPING MATERIAL SPECIFICATION (B4A - CLASS 300#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 43 of 68

PIPING CLASS

:

B4A, 300 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

LOW TEMPERATURE SERVICE

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

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: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4.

IMPACT TESTING IS REQUIRED

5.

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.

6.

FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007

SPECIAL NOTES ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL

FLANGED, TO BE KEPT MINIMUM

PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”. S-05-01-004

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 44 of 68

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18

18

16

16

14

T

14

T

T

12

T

T

T

10

T

T

T

T

8.0

T

T

T

T

12 10 8.0 6.0

T

5.0 4.0

T

T

T

T

W

W

3.5 T

T

T

W

W

W

W

T

T

T

W

W

W

W

W

T

S

S

S

S

S

S

S

2.5

3.0 2.5

2.0 1.5

T

2.0 1.5

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

0.5

6.000

8.000

10.000

12.000

14.000

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

T

2.500

T

T

2.000

T

T

1.500

1.0

1.250

T T

1.000

1.25

0.500 0.750

1.25

0.5

4.0 3.5

3.0

0.75

6.0 5.0

1.0

RUN PIPE (SIZES IN INCH) – B4A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 45 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch)

Item Type

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Dim. STD

Material

Description

Pipe Group (B4A) PIPE

00.500

00.750

S160

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A 333 GR.6

BE, 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

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 333 GR.6

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 333 GR.6

PBE, SEAMLESS

Flange Group (B4A) 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

ASMEB16.48

ASTM A 350 GR. LF2

300, FF/125 AARH

SPCR &BLIND

10.000

14.000

ASMEB16.48

ASTM A 350 GR. LF2

300, FF/125 AARH

Fitting Group (B4A) ELBOW.90

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.90

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.45

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.45

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.45

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 350 GR.LF2

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 350 GR.LF2

SW, 3000

T.EQUAL

02.000

14.000

B-16.9

ASTM A 420 GR.WPL6

BW

M

M

M

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 46 of 68

T.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

T.RED

02.000

14.000

M, M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.CONC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

REDUC.ECC

02.000

14.000

M,M

B-16.9

ASTM A 420 GR.WPL6

BW

SWAGE.CONC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

SWAGE.ECC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

CAP

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O’ let group (B4A) SOCKOLET

00.500

0.750

MSSSP97

ASTM A 350 GR.LF2

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 350 GR.LF2

SW, 3000

WELDOLET

02.000

4.000

MSSSP97

ASTM A 350 GR.LF2

BW

M, XXS

Valves Group (B4A) VLV.GATE

00.500

01.500

API602

BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B-16.11

VLV.GATE

00.200

24.000

API600

BODY-ASTM A 352 GR. LCB, TRIM-STELLITED, STEM SS304

FLGD,300, B16.5, RF/125AARH

VLV.GLOBE

00.500

01.500

BS5352

BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B-16.11

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 47 of 68

VLV.GLOBE

02.000

12.000

BS1873

BODY-ASTM A 352 GR.LCB, TRIM-STELLITED, STEM SS304

FLGD,300, B16.5, RF/125AARH

VLV.CHECK

00.500

1.500

BS5352

BODY-ASTM A 350, GR.LF2, TRIM-STELLITED

SW,800, 3000, B-16.11

VLV.CHECK

02.000

24.000

BS1868

BODY-ASTM A 352, GR.LCB, TRIM-STELLITED

FLGD,300, B16.5, RF/125AARH

VLV.BALL

00.500

16.000

BS5351

BODY-ASTM A 352, GR.LCB/ ASTM A350, GR.LF2, TRIM-BODY SEATRPTFE

FLGD,300, B16.5, RF/125AARH

00.500

14.000

B18.2

BOLT: A 320 GR.L7, NUT:A194 GR.4

14.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

SPIRAL, 300

GAIL STD.

B:A516GR.70(NORM);

CONETYPE,300,FF/125AARH

Bolt Group (B4A) BOLT.STUD

Gasket Group (B4A) GASKET

00.500

Trap/ Strainer Group (B4A) STRNR.TEMP

01.500

14.00

INT:SS304 STRNR.TEMP

00.500

1.500

GAIL STD.

B:A350GR.LF2

SW, Y-TYPE, 800

(NORM);INT:SS304 STRNR.TEMP

02.000

14.000

M

GAIL STD.

B:A420GR.WPL6;

BW, T-TYPE

INTR:SS304

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 48 of 68

ANNEXURE G

PIPING MATERIAL SPECIFICATION (D4A - CLASS 600#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 49 of 68

PIPING CLASS

:

D4A, 600 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

LOW TEMPERATURE SERVICE

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

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: RADIOGRAPHY

:

ALL BUTT WELDS

-

100%

MPI

:

SOCKET WELDS

-

100%

3.

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4.

IMPACT TESTING IS REQUIRED

5.

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.

6.

FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007 SPECIAL NOTES ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL

FLANGED, TO BE KEPT MINIMUM

PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”, REFER STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”. REFER STD. S-05-01-004

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 50 of 68

70

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18 16

T

14 12 10

T

8.0 6.0

T

18

T

16 14

T

T

T

T

T

T

T

12

T

T

T

T

10

T

T

T

T

T

T

8.0

T

T

T

T

T

T

W

6.0

T

T

T

W

W

W

W

5.0

5.0

4.0

T

3.5 3.0

T

T

T

W

W

W

W

W

W

2.5 1.5

T

T

T

T

W

W

W

W

W

W

W

T

S

S

S

S

S

S

S

S

S

2.0 1.5

S

S

S

S

S

S

S

S

S

0.75

T T

T

T

S

S

S

S

S

S

S

S

S

S

0.5

6.000

8.000

10.000

12.000

14.000

16.000

1.0

18.000

S

S

5.000

S

S

4.000

S

S

3.500

S

S

3.000

S

T

2.500

T

T

2.000

T

T

1.500

1.0

1.250

T T

1.000

1.25

0.500 0.750

1.25

0.5

3.0 2.5

2.0

0.75

4.0 3.5

RUN PIPE (SIZES IN INCH) – D4A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 51 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch)

Item Type

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Dim. STD

Material

Description

Pipe Group (D4A) PIPE

00.500

00.750

S160

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

01.000

01.500

XS

B 36.10

ASTM A 333 GR.6

PE, SEAMLESS

PIPE

02.000

02.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

03.000

3.000

STD

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

4.000

4.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

06.000

06.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

08.000

8.000

XS

B 36.10

ASTM A 333 GR.6

BE, SEAMLESS

PIPE

10.000

10.000

XS

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

NIPPLE

00.500

00.750

M

B 36.10

ASTM A 333 GR.6

PBE,SEAMLESS

NIPPLE

01.000

01.500

M

B 36.10

ASTM A 333 GR.6

PBE, SEAMLESS

Flange Group (D4A) 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

ASMEB16.48

ASTM A 350 GR. LF2

600, FF/125 AARH

SPCR &BLIND

10.000

18.000

ASMEB16.48

ASTM A 350 GR. LF2

600, FF/125 AARH

Fitting Group (D4A) ELBOW.90

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.90

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 52 of 68

ELBOW.90

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.90

16.000

18.000

M

B-16.9

ASTM A 420 GR.WPL6-W

BW, 1.5D

ELBOW.45

00.500

0.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

ELBOW.45

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

ELBOW.45

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW, 1.5D

ELBOW.45

16.000

18.000

M

B-16.9

ASTM A 420 GR.WPL6-W

BW, 1.5D

T.EQUAL

00.500

00.750

B 16.11

ASTM A 350 GR.LF2

SW, 6000

T.EQUAL

01.000

01.500

B 16.11

ASTM A 350 GR.LF2

SW, 3000

T.EQUAL

02.000

14.000

M

B-16.9

ASTM A 420 GR.WPL6

BW

T.EQUAL

16.000

18.000

M

B-16.9

ASTM A 420 GR.WPL6-W

BW

T.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

T.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

T.RED

02.000

14.000

M, M

B-16.9

ASTM A 420 GR.WPL6

BW

T.RED

16.000

18.000

M, M

B-16.9

ASTM A 420 GR.WPL6-W

BW

SWAGE.CONC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

SWAGE.ECC

00.500

03.000

M,M

BS3799

ASTM A 350 GR.LF2

PBE

CAP

00.500

0.750

B-16.11

ASTM A 350, GR.LF2

SCRF, 6000

CAP

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SCRF, 3000

CAP

02.000

18.000

B-16.9

ASTM A 420 GR.WPL6

BW

PLUG

00.500

0.750

B-16.11

ASTM A 350, GR.LF2

SCRM, 6000

PLUG

01.000

1.500

B-16.11

ASTM A 350 GR.LF2

SCRM, 3000

CPLNG.FULL

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.FULL

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG-HALF

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.HALF

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

CPLNG.LH

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

CPLNG.LH

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW,3000

CPLNG.RED

00.500

00.750

B-16.11

ASTM A 350 GR.LF2

SW, 6000

M

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 53 of 68

CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O’ let group (D4A) SOCKOLET

00.500

0.750

MSSSP97

ASTM A 350 GR.LF2

SW, 6000

SOCKOLET

01.000

01.500

MSSSP97

ASTM A 350 GR.LF2

SW, 3000

WELDOLET

02.000

6.000

MSSSP97

ASTM A 350 GR.LF2

BW

M, XXS

Valves Group (D4A) VLV.GATE

00.500

01.500

API602

BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B-16.11

VLV.GLOBE

00.500

01.500

BS5352

BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304

SW,800, 3000,B-16.11

VLV.CHECK

00.500

1.500

BS5352

BODY-ASTM A 350, GR.LF2, TRIM-STELLITED

SW,800, 3000, B-16.11

VLV.PLUG

00.500

1.500

BS5353

BODY-ASTM A 350, GR.LF2, PLUG:A350 GR.LF2+0.003” ENP

SW,800, 3000, B-16.11

VLV.PLUG

02.000

18.000

API-6D

BODY-ASTM A 352, GR.LCB/ ASTM A350, GR.LF2, TRIM-SS 304/ SS316

BW, 600, B-16.25

18.000

B18.2

BOLT: A 320 GR.L7, NUT:A194 GR.4

18.000

B16.20ANSI B16.5

SP,WND, SS316+CAF

Bolt Group (D4A) BOLT.STUD

00.500

Gasket Group (D4A) GASKET

00.500

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPIRAL, 600

SPECIFICATION 0001-01-05-02-001

REV-0 Page 54 of 68

ANNEXURE H

PIPING MATERIAL SPECIFICATION (A93A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 55 of 68

PIPING CLASS

:

A93A, 150 #

BASE MATERIAL

:

CARBON STEEL

CORROSION ALLOWANCE

:

1.5 MM

SPECIAL REQUIREMENT

:

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

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

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

ALL

FLANGED, TO BE KEPT MINIMUM

PIPE JOINTS

1.5” & BELOW

SW COUPLING

2.0” & ABOVE

BUTT WELDED

ON LINES ≤1.5”

REFER GAIL STD.S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”REFER STD. S-05-01-003.

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75”

SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 56 of 68

70

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18

18

16

16

14 12

14 12

T

R

T

R

R

10

T

R

R

R

8.0

T

P

R

R

R

6.0

R

P

R

R

R

10 8.0 6.0

T

5.0

5.0

4.0

T

3.5

3.5

3.0

T

P

R

P

R

R

R

T

P

P

R

P

R

R

R

T

H

H

H

H

H

H

H

2.5

3.0 2.5

2.0 1.5

T

2.0 1.5

H

1.0

H

H

0.75

T

T

T

H

H

H

H

H

H

H

H

0.5

10.000

12.000

14.000

5.000

H

H

4.000

H

H

3.500

H

H

3.000

H

H

2.500

H

H

2.000

H

H

1.500

H

T

1.250

T

T

0.500 0.750

T

T T

1.000

1.0 0.75

8.000

1.25

6.000

1.25

0.5

4.0

RUN PIPE (SIZES IN INCH) – A93A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 57 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch)

Item Type

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Dim. STD

Material

Description

Pipe Group (A93A) PIPE

00.500

01.500

HVY

IS-1239-I

IS-1239 (BLACK)

PE, C. WELDED

PIPE

02.000

06.000

HVY

IS-1239-I

IS-1239 (BLACK)

BE, C. WELDED

PIPE

08.000

12.000

6.0

IS-3589

IS-3589 GR.410

BE, WELDED

PIPE

14.000

14.000

8.0

IS-3589

IS-3589 GR.410

BE, SEAMLESS

NIPPLE

00.500

01.500

HVY

IS-1239 (BLACK)

PBE, C. WELDED

M

B-16.5

ASTM A 105

150, RF/125 AARH

Flange Group(A93A) FLNG. SW

00.500

1.50

FLNG. SO

02.000

14.000

B-16.5

ASTM A 105

150, RF/125 AARH

FLNG.BLIND

00.500

14.000

B-16.5

ASTM A 105

150, RF/125 AARH

FLNG.FIG.8

00.500

8.000

ASMEB16.48

ASTM A 105

150, FF/125 AARH

SPCR &BLIND

10.000

14.000

ASMEB16.48

ASTM A 105

150, FF/125 AARH

B-16.11

ASTM A 105

SW, 3000

Fitting Group(A93A) ELBOW.90

00.500

1.500

ELBOW.90

02.000

6.000

STD

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELBOW.90

8.000

14.000

M

B-16.9

ASTM A 234 GR.WPB-W

BW, 1.5D

ELBOW.45

00.500

1.500

B-16.11

ASTM A 105

SW, 3000

ELBOW.45

02.000

6.000

STD

B-16.9

ASTM A 234 GR.WPB

BW, 1.5D

ELBOW.45

08.000

14.000

M

B-16.9

ASTM A 234 GR.WPB-W

BW, 1.5D

T.EQUAL

00.500

01.500

B 16.11

ASTM A 105

SW, 3000

T.EQUAL

02.000

6.000

B 16.9

ASTM A 234 GR.WPB

BW

STD

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 58 of 68

T.EQUAL

08.000

14.000

T.RED

00.500

01.500

T.RED

02.000

06.000

T.RED

08.000

REDUC.CONC

M

B-16.9

ASTM A 234 GR.WPB-W

BW

B-16.11

ASTM A 105

SW, 3000

STD.,STD

B-16.9

ASTM A 234 GR.WPB

BW

14.000

M, M

B-16.9

ASTM A 234 GR.WPB-W

BW

02.000

06.000

STD.,STD

B-16.9

ASTM A 234 GR.WPB

BW

REDUC.CONC

08.000

14.000

M, M

B-16.9

ASTM A 234 GR.WPB-W

BW

REDUC.ECC

02.000

06.000

STD.,STD

B-16.9

ASTM A 234 GR.WPB

BW

REDUC.ECC

08.000

14.000

M, M

B-16.9

ASTM A 234 GR.WPB-W

BW

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105

PBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105

PBE

CAP

00.500

1.500

B-16.11

ASTM A 105

SCRF, 3000

CAP

02.000

6.000

STD

B-16.9

ASTM A 234 GR.WPB

BW

CAP

08.000

14.000

M

B-16.9

ASTM A 234 GR.WPB

BW

CPLNG.FULL

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.HALF

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.LH

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

CPLNG.RED

00.500

01.500

B-16.11

ASTM A 105

SW, 3000

UNION

00.500

01.500

BS-3799

ASTM A 105

SW, 3000

Valves Group(A93A) VLV.GATE

00.500

01.500

API-602

BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR. STEEL

SW,800, 3000,B-16.11

VLV.GATE

02.000

24.000

API-600

BODY-ASTM A 216 GR.WCB, TRIM-13% CR. STEEL

FLGD, 150, B16.5, RF/125AARH

VLV.GLOBE

00.500

01.500

BS-5352

BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR. STEEL

SW,800, 3000,B-16.11

VLV.GLOBE

02.000

16.000

BS-1873

BODY-ASTM A 216 GR.WCB, TRIM-13% CR. STEEL

FLGD, 150, B16.5, RF/125AARH

VLV.CHECK

00.500

1.500

BS-5352

BODY-ASTM A 105, TRIMSTELLITED,

SW,800, 3000,B-16.11

VLV.BTRFLY

02.000

24.000

BS-5155

BODY-ASTM A 216 GR. WCB, TRIM-13% CR.STEEL,

WAFL, 150, B16.5, WAF/ 125AARH

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 59 of 68

Bolt Group(A93A) BOLT.STUD

00.500

14.000

B18.2

BOLT: A 193 GR.B7, NUT:A194 GR.2H

14.000

B16.21ANSI B16.5

IS-2712-GR. W/3

RING, 150, 2MM

MNF’STD

B:A105;INT;SS304

SW, Y-TYPE, 800

Gasket Group(A93A) GASKET

00.500

Trap/ Strainer Group(A93A) STRNR.PERM

00.500

1.500

STRNR.PERM

02.000

6.000

M

GAIL STD

B:A234GR.WPB;INT:SS304

BW, T-TYPE

STRNR.PERM

08.000

14.000

M

GAIL STD

B:A234GR.WPBW;INT:SS304

BW, T-TYPE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 60 of 68

ANNEXURE I

PIPING MATERIAL SPECIFICATION (J2A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 61 of 68

PIPING CLASS

:

J2A, 150 #

BASE MATERIAL

:

CS (Galv.)

CORROSION ALLOWANCE

:

0 MM

SPECIAL REQUIREMENT

:

TEMPERATURE (Deg. C) AND PRESSURE ( Kg/Sq. cm g ) RATINGS

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

ITEM

SIZE

DESCRIPTION

MAINTENANCE JOINTS

1.5” & BELOW

UNIONS (SCRF) TO BE KEPT MINIMUM

2” & ABOVE

FLANGED (SCREWED) TO BE KEPT MINIMUM

PIPE JOINTS

UP TO 6”

SCREWED COUPLING

DRAINS

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75” REFER STD. S-05-01-004

ON LINES ≤1.5”

REFER GAIL STD. S-05-01-003

ON LINES ≥2.0”

AS PER P&ID OR 0.75”. REFER STD. S-05-01-004

TEMP. CONN

1.5”

FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005

PRESS. CONN

0.75”

SCREWED NIPPLE WITH VALVE TO SPEC. S-05-01-006

VENTS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 62 of 68

70

70

68

68

66

66

64

64

62

62

60

60

58

58

56

56

54

54

52

52

50

50

48

48

46

46

44

44

42

42

40

40

38

38

36

36

34

34

32

32

30

30

28

28

26

26

24

24

22

22

20

20

18

18

16

16

14

14

12

12

10

10

8.0

8.0

6.0

T

5.0 4.0

T

T

3.5

4.0 3.5

3.0

T

T

T

2.5

3.0 2.5

2.0 1.5

T

T

T

T

T

T

T

T

T

1.25

2.0 1.5 1.25

T

T

T

T

1.0

6.000

0.5

5.000

0.75

T

4.000

T

T 3.500

T

T 3.000

T

T 2.500

T

T

2.000

T

T

1.500

T

T

1.250

T T

1.000

0.75

T

0.750

T

0.500 0.500

1.0 0.5

6.0 5.0

RUN PIPE (SIZES IN INCH) – J2A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 63 of 68

CODE

DESCRIPTION

F H P R S

SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch)

Item Type

T W I X L

TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Dim. STD

Material

Description

IS-1239-I

IS-1239 (GALV)

SCRM, WELDED

Pipe Group (J2A) PIPE

00.500

06.000

HVY

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

ASMEB16.48

ASTM A 105 (GALV.)

150, FF/125 AARH

Fitting Group(J2A) ELBOW.90

00.500

1.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

ELBOW.90

02.000

6.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

ELBOW.45

00.500

1.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

ELBOW.45

02.000

6.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

T.EQUAL

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

T.EQUAL

02.000

6.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

T.RED

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

T.RED

02.000

6.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

SWAGE.CONC

00.500

03.000

M,M

BS-3799

ASTM A 105 (GALV.)

TBE

SWAGE.ECC

00.500

03.000

M,M

BS-3799

ASTM A 105 (GALV.)

TBE

CAP

00.500

1.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CAP

02.000

6.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

CPLNG.FULL

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CPLNG.HALF

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CPLNG.LH

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

CPLNG.RED

00.500

01.500

B-16.11

ASTM A 105 (GALV.)

SCRF, 3000

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 64 of 68

UNION

00.500

06.000

IS-1239-II

IS-1239 (PART-II) (GALV.)

SCRF, NA

Valves Group(J2A) VLV.GATE

00.500

01.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2

SCRF, CL.2, 3000, B1.20.1

VLV.GATE

02.000

6.000

IS:780

BODY-IS 210,GR.FG 200, TRIM-IS 320 ALLOY HT2

FLGD, PN 1.6, B 16.1,FF/125AARH

VLV.GLOBE

00.500

01.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2

SCRF, CL.2, 3000, B1.20.1

VLV.CHECK

00.500

1.500

IS:778 CL.2

BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2

SCRF, CL.2, 3000, B1.20.1

VLV.CHECK

02.000

6.000

IS:5312 (PT-1)

BODY-IS 210 GR.FG 200, TRIM-IS 320 ALLOY HT2

FLGD, PN1.6, B-16.1, FF/125AARH

00.500

6.000

B18.2

BOLT: A 307, GR.B (GALV), NUT:A563 GR.B (GALV)

6.000

B16.21ANSI B16.5

BUTYL RUBBER

Bolt Group(J2A) BOLT.M/C

Gasket Group(J2A) GASKET

00.500

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

FULL FACE, 150, 2MM

SPECIFICATION 0001-01-05-02-001

REV-0 Page 65 of 68

ANNEXURE-I LIST OF ATTACHMENTS

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

DOCUMENT Jack Screw for Spectacle Blind (150#, 300#, 600#) Jack Screw for Spacer and Blind (150#, 300#, 600#) Vents & Drains on lines (On lines 1- ½ “ & Below) Vents & Drains on lines (On lines 2 “ & above) Wells Installation 1- ½ “ Dia Taps Pressure Tappings – PG, PT, PI, PA, PC etc Dimn. For Handle Projections for Spacers and Blinds T-Strainer Type-1 2"-4" (150# RF, 300# RF and RTJ, 600# RF and RTJ) T-Strainer Type-1 6"-24" (150# RF, 300# RF and RTJ, 600# RF and RTJ) Standard Specification of LSAW pipe Standard Specification of HSAW pipe Standard Specification for Long Radius Bends for onshore Pipelines Specification for Barred Tees Specification for Insulating Joints for Onshore Pipelines Standard Specification for Seamless fittings & Flanges, Size up to DN 400 mm (16”) Specification for flanges & Welded Fittings (Size DN 450 mm (18") and above Specification for Seamless fittings & Flanges, Size up to DN 400 mm (16”) Technical Notes for Valves Technical Notes for Pipes Technical Notes for Butt Welded, Socket Welded and Screwed Fittings Technical Notes for Flanges, Spectacle Blinds and Drip Rings Technical Notes for Bolts and Nuts Technical Notes for Gaskets Inspection and Test Plan for Gaskets Specification for Shop and Field Painting Standard Specification for Fabrication and Erection of Piping Standard specification for Inspection, Flushing and Testing of Piping system Standard Specification of “Non-Destructive PIPING MATERIAL SPECIFICATION

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. S-05-01-001

REV . 0

S-05-01-002

0

S-05-01-003

0

S-05-01-004

0

S-05-01-005 S-05-01-006 S-05-01-007

0 0 0

S-05-01-008

0

S-05-01-009

0

S-04-02-001 S-04-02-002 S-04-02-015

0 0 0

S-04-02-016 S-04-02-019

0 0

S-04-02-013

0

S-04-02-014

0

S-04-02-013

0

S-05-02-002 S-05-02-001 S-05-02-003

0 0 0

S-05-02-004

0

S-05-02-005 S-05-02-006 S-14-06-001 S-05-02-014 S-05-02-011

0 0 0 0 0

S-05-02-013

0

S-05-02-012

0

SPECIFICATION 0001-01-05-02-001

REV-0 Page 66 of 68

29 30 31 32 33 34 35

Examination of Piping” Standard Specification for Scraper Traps for Onshore Pipelines Standard Specification for Quick Opening End Closure Standard Specification for Pig Signaller for Onshore Pipelines Standard Specification of Plug Valve Standard Specification of Ball Valve Standard Specification of Gas Powered Valve Actuators Standard Specification for Positive Material Identification at Vendor’s Works.

S-04-02-017

0

S-04-02-024

0

S-04-02-018

0

S-04-02-008 S-04-02-007 S-04-02-012

0 0 0

S-14-02-001

0

LIST OF DATASHEETS Sl. TITLE No. 1 Data Sheet for Scraper Launcher/ Receiver 2 Data Sheet for Pig Signaller 3 Data Sheet for Quick Opening End Closure 4 Data Sheet for Insulating Joints 5 Data Sheet for Flow Tee (Barred Tee) 18" X 18" , 600# 6 Data Sheet for Flow Tee (Barred Tee) 18" X 12" , 600# 7 Data Sheet for Flow Tee (Barred Tee) 18" X 8" , 600# 8 Data Sheet for Ball Valve 9 Data Sheet for Gas Powered Valve Actuator 10 Data Sheet for Plug Valve 11 Data Sheets for Gate Valves of Size below 2”

DATA SHEET NO. 0001-01-04-04-PL/PR-001

RE V. 0

0001-01-04-04-PSG-001 0001-01-04-04-QOEC-001

0 0

0001-01-04-04-IJ-001 0001-01-04-04-FLT-001

0 0

0001-01-04-04-FLT-002

0

0001-01-04-04-FLT-003

0

0001-01-05-04-BV-001 0001-01-04-04-GVA-001

0 0

0001-01-04-04-PV -001 0001-01-05-04-GV-001

0 0

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 67 of 68

TABLE-3

PIPELINE SPECIALITY ITEMS MAINLINE (FROM SCRAPER LAUNCHER TO SCRAPER RECEIVER) Sl. No. ITEM MATERIAL DESCRIPTION LONG RADIUS BENDS • API 5L Gr. X-70 PSL2, 11.7 mm wall thickness 1 (R=6D) FOR PIPELINES SUITABLE FOR PIGGING

for 18” dia. pipeline for Sultanpur to Neemrana • API 5L Gr. X-60 PSL2, 9.5 mm wall thickness for 12” dia. pipeline for Bhiwadi. • API 5L Gr. X-60 PSL2, 7.8 mm wall thickness for 10” dia. pipeline for Gurgaon 18 X 18 X 18 - MSS-SP-75 Gr. WPHY-70 18 X 18 X 12 - MSS-SP-75 Gr. WPHY-70 18 X 18 X 8 - MSS-SP-75 Gr. WPHY-70 Monoblock type • Pups / Body: 18” – API 5L Gr. X 70, PSL-2 / ASTM A694 Gr. F70 (CHARPY) 12” - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 10” - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 8” - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY)

2

FLOW TEES (BARRED TEES)

3

INSULATING JOINTS

4

SCRAPPER LAUNCHER & RECIEVER

18” – Body: API 5L Gr. X-70 PSL2 Reducer: MSS-SP-75 Gr. WPHY-70 Neck: API 5L Gr. X-70 PSL2 QOEC: ASTM A 105 (CHARPY)

5

PIG SIGNALLER

Body: ASTM A 105 (CHARPY) Internals: SS316

For Mainline Items, corrosion allowance shall be 0.0 mm except for scraper traps where 3 mm corrosion allowance shall be taken.

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 68 of 68

WELDING SPECIFICATION FOR MAIN LINE

FOR TRANSPORTATION OF GAS SPUR LINE CHAINSA – JHAJJAR PIPELINE

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 1 of 52

Copyright GAIL – All rights reserved

CONTENTS 1.0

SCOPE

2.0

APPLICABLE CODES AND STANDARDS

3.0

BASE MATERIAL

4.0

WELDING CONSUMABLES

5.0

EQUIPMENT AND ACCESSORIES

6.0

WELDING PROCESSES

7.0

BEVEL CLEANING AND BEVEL INSPECTION

8.0

ALIGNMENT AND SPACING

9.0

WEATHER CONDITIONS

10.0

WELDING

11.0

HEAT TREATMENT

12.0

INSPECTION AND TESTING

13.0

REPAIR OF WELDS ANNEXURE – 1 : DESTRUCTIVE TESTING ANNEXURE – 2 : ULTRASONIC TESTING ANNEXURE – 3 : AUTOMATED ULTRASONIC TESTING ANNEXURE – 4 : RADIOGRAPHY TESTING

EXHIBIT-A : ELECTRODE QUALIFICATION TEST RECORD EXHIBIT-B : STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION EXHIBIT-C : WELDING PROCEDURE QUALIFICATION TEST RECORD EXHIBIT-D : WELDER QUALIFICATION TEST RECORD EXHIBIT-E : WELDERS IDENTIFICATION CARD EXHIBIT-F : RADIOGRAPHIC PROCEDURE FOR PIPE WELDING

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 2 of 52

Copyright GAIL – All rights reserved

1.0

SCOPE 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. The welded pipe joints shall include the following: 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.

2.0

APPLICABLE CODE AND STANDARDS 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.

b)

Standard for Welding of Pipelines and Related Facilities, API 1104.

c)

Specification for Welding Electrodes and Filler Materials, ASME Sec. II Part C

d)

Non-Destructive Examination, ASME Sec. V.

e) 3.0

Welding and Brazing Qualifications, ASME Sec. IX

BASE MATERIAL In general carbon steel is used in this specification. The details of material specifications are given in the welding Specification Chart attached along with other project data sheets. The CONTRACTOR will arrange and maintain the record of test certificates of all the materials for the reference of the welding engineer.

4.0

WELDING CONSUMABLES 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 3 of 52

Copyright GAIL – All rights reserved

b) The welding electrodes/filler wires supplied by the CONTRACTOR shall conform to the class specified in the welding specification chart attached along with other project data sheets. The materials shall be of the make approved by 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. f) All electrodes/filler wire shall be purchased in sealed containers and stored properly to prevent deterioration. Except the cellulosic coated electrodes, the electrodes removed from the containers shall be kept in the holding ovens, at the temperature recommended by the electrode(s) manufacturer(s). Oven shall be used for the low hydrogen electrode only. Out-of-the oven time of electrodes before they are consumed shall not exceed the limits recommended by the electrode manufacturer(s). The welding consumables shall be handled with care to avoid any damage to the flux covering. Different grades of welding consumables shall be stored separately. Cellulosic electrodes shall be used as per the specific recommendation made by the manufacturer. 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. 1. Argon gas complying with BS 4365. 2. Carbon dioxide gas complying with type 1 specified in BS 4105 3. Gas mixtures that have been proved to be satisfactory as a result of procedure approval tests.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 4 of 52

Copyright GAIL – All rights reserved

When a gas mixture is used, which has specified additions viz.. 2% O2, 5% CO2, the variation of such addition shall not exceed +10% of that stated. Moisture content shall correspond to a dew point of -300C or lower. 5.0

EQUIPMENT AND ACCESSORIES 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.

6.0

WELDING PROCESSES

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. 6.1.3 Tie-Ins and Crossings Any of the processes specified above as per qualified procedures. 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 5 of 52

Copyright GAIL – All rights reserved

6.3

A combination of different welding processes or a combination of welding consumables of different classes/makes could be employed for a particular joint, only after duly qualifying the welding procedures to be adopted and obtaining the approval of the COMPANY.

7.0

BEVEL CLEANING/BEVEL INSPECTION 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.

8.0

ALIGNMENT AND SPACING 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 GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 6 of 52

Copyright GAIL – All rights reserved

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. 9.0

WEATHER CONDITIONS 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 10.1

Root Pass 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 GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 7 of 52

Copyright GAIL – All rights reserved

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. d) Any deviations from the recommended welding techniques and welding consumables indicated in the welding specification chart shall be permitted only after obtaining written approval of the COMPANY. e) Welding shall be continuous and uninterrupted during a pass. f)

On completion of each run, craters, welding irregularities, slag etc. shall be removed by grinding and chiseling.

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)

i) 10.2

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. Peening shall not be used.

Joint Completion 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 8 of 52

Copyright GAIL – All rights reserved

The welding speed selected shall enable production of a bead which is sufficiently thick and with consistent fusion and without any under cutting. 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 Preheating, if required, shall be carried out as per the following: a) Preheating requirements for the various materials shall be as per the welding specification charts. b) Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners is allowed only in exceptional cases with the permission of the COMPANY. 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 9 of 52

Copyright GAIL – All rights reserved

12.0

INSPECTION AND TESTING

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: i) ii) iii) iv)

To check the conformance to relevant standards and suitability of various welding equipment and the welding performance. To supervise the welding procedure qualification. To supervise the welders’ performance qualification. To check whether shop/field welding being executed is in conformity with the relevant specifications and codes of practice followed in pipe construction.

c) The CONTRACTOR shall intimate sufficiently in advance the commencement of the qualification tests, welding works and acceptance tests to enable the authorized Inspector to be present to supervise them. 12.2

Welding Procedure Qualification a) Welding procedure qualification shall be carried out in accordance with the relevant requirements of API 1104 latest edition or other applicable codes and job requirements by the CONTRACTOR at his expense. The CONTRACTOR shall submit the welding procedure specifications in format as per Exhibit-C attached, immediately after the receipt of the order. 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. GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 10 of 52

Copyright GAIL – All rights reserved

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. c) No welder shall be permitted to work without the possession of identity card. d) If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expense of the CONTRACTOR.

12.4

Visual Inspection 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

Non-Destructive Examination

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 GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 11 of 52

Copyright GAIL – All rights reserved

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.

b)

When welds are repaired.

c)

When in the opinion of COMPANY, Radiography Testing is required to confirm or clarify defects indicated by Ultrasonic Testing.

d)

Welding of transition piece of pipe. In addition, Radiography inspection may be required for certain critical welds of the pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet and groove welds, other than those AUT examined, shall be subjected to Dye-Penetrant /MP testing followed by manual Ultrasonic testing. The non-destructive testing system used for inspecting welds must by approved by the COMPANY.

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: a)

On the first 10 welded joints corresponding to each automatic GMAW and semi-automatic FCAW welding procedures used.

b)

When welds are repaired.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 12 of 52

Copyright GAIL – All rights reserved

c)

12.5.4

When in the opinion of COMPANY, Ultrasonic inspection is required to confirm or clarify defects indicated by Radiography. In addition, Ultrasonic inspection may be required for certain critical welds of the pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet and groove welds, other than those are subjected to Radiography, shall be subjected to Dye-Penetrant/MP inspection. The non-destructive testing system used for inspecting welds must by approved by the COMPANY. Acceptance Criteria

Weld quality as judged on the basis of the acceptability criteria mentioned below:

12.6

i)

Any weld, which as a result of Radiography and/or Ultrasonic examination in the opinion of COMPANY exhibits imperfections greater than the limits stated in API 1104 latest edition or as superseded in this specification, shall be considered defective and shall so be marked with an identification point marker.

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.

Destructive Testing 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.

13.0 REPAIRS OF WELDS 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. A separate welding procedure specification sheet shall be formulated and qualified by CONTRACTOR for repair welds simulating the proposed repair to be carried out. Separate procedures are required to be qualified for (a) through thickness repair (b) external repair and (c) internal repair. Welders shall be qualified in advance for repairs. The root pass, for repairs opening the root, shall be replaced by the vertical uphill technique. The procedure shall be proven by satisfactory procedure test to APIGAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 13 of 52

Copyright GAIL – All rights reserved

1104 including the special requirements of the specification, and shall also be subjected to Metallographic examination, Hardness surveys and Charpy V-Notch testing to determine the effects of repair welding on the associated structure. 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. 13.2

Weld Rejected by Accumulation of Defects Where a weld is rejected by the accumulation of defect as defined by API-1104 and this specification, repairs within these limitations are permitted. Defects in the filling and capping passes shall be repaired preferentially.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 14 of 52

Copyright GAIL – All rights reserved

ANNEXURE – 1 (DESTRUCTIVE TESTING) 1.0 1.1

DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS PREPARATION OF SPECIMEN 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.

1.2

TENSILE STRENGTH 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 15 of 52

Copyright GAIL – All rights reserved

TABLE – 1

1.3

NICK-BREAK TEST

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

MACROSCOPIC INSPECTION

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 Specimens shall be carefully examined under the microscope, with a magnification of at least 25 x. The COMPANY may ask for a macrograph with 5x magnification for documentation purposes.

1.4.3 Requirements

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 16 of 52

Copyright GAIL – All rights reserved

Under macroscopic examination, the welded joints shall reveal good penetration and fusion without any defect exceeding the limits stated in the evaluation criteria of the Nick-Break test. 1.5

HARDNESS TEST

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

CHARPY V-NOTCH IMPACT TESTING

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 VNotch 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:

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 17 of 52

Copyright GAIL – All rights reserved

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 The impact energy values shall be as follows:

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.

1.7

BEND TEST REQUIREMENTS 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: Radius of the Plunger `A' = 2t

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 18 of 52

Copyright GAIL – All rights reserved

Radius of the die. `B' = 3t + 1.6 mm Width of the die. `C' = 50.8 Where t = thickness of the specimen 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 19 of 52

Copyright GAIL – All rights reserved

ANNEXURE – 2 (ULTRASONIC TESTING) 1.0

ULTRASONIC TESTING In addition to the Radiography testing, Ultrasonic testing is required as per conditions listed in paragraph 12.5 of this specification. This section concerns manual Ultrasonic inspection. However Ultrasonic inspection by automatic equipment may be used if approved by the COMPANY.

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.

1.2

SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE The CONTRACTOR shall present a Specification describing the proposed Ultrasonic testing procedure qualification. This specification shall state the following information including all the parameters described in API 1104:

1.3

a)

Type of Ultrasonic testing equipment to be used

b)

Type and dimensions of transducers

c)

Frequency range

d)

Details for calibration

e)

Coupling medium

f)

Inspection technique

g)

Reference to the welding procedure where it is intended to adopt the specification

h)

Temperature range of the joints to be inspected

I)

Record details.

QUALIFICATION OF ULTRASONIC TESTING PROCEDURE

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 20 of 52

Copyright GAIL – All rights reserved

Before the actual inspection begins, the COMPANY may require the qualification test of the Ultrasonic testing procedure. The qualification test shall be conducted under normal operating conditions on some weld made by the CONTRACTOR according to the same production procedure, where there are typical defects are intended to be detected. The qualification test shall be conducted in the presence of the COMPANY’s representative. The Ultrasonic inspection procedure shall be approved by the COMPANY. 1.4

TEST PROCEDURE 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 equipment shall include but not be limited to the following: a)

Ultrasonic equipment and coupling medium

b)

Sample sections for calibration of instruments

c)

Equipment for cleaning of surface to be examined

d)

Rules calibrated in centimeters for exact location of the position of defects.

The characteristics of the above listed instruments and equipment shall guarantee: a)

The required standards of the inspection procedure previously established and approved by the COMPANY are satisfied

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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 21 of 52

Copyright GAIL – All rights reserved

All the instruments and equipment necessary for carrying out Ultrasonic inspection on site shall satisfy the requirements laid down by the public boards of institutions that regulate `safety at work'. 1.5

ULTRASONIC INSTRUMENTS The Ultrasonic instruments shall have the following: a)

Pulse-echo type; able to generate, receive and display on the screen of a Cathode Ray Tube (CRT); pulse at frequencies between 1 and 6 MHz. The useful part of the CRT screen shall be at least 70mm wide and at least 50mm high. Variable amplification, with steps of 1 or 2 dB over a range of a least 60 dB.

b)

The regulation control shall be accurate to within ±1 dB and this accuracy shall be certified by the instrument manufacturer.

c)

May be powered by a battery or an electric generator. In the first case, the autonomy of operation (endurance) of the instrument shall be sufficient to carry out work without frequent interruptions, and the instrument shall be equipped with an automatic switch, which switches if off when the battery runs down. In the second case, there must be a voltage stabilizing device with a tolerance of ±2 volts.

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.

1.6

REFERENCE SAMPLE PIECES 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 calibration, qualification of the testing procedure shall be done as provided in API 1104.

1.9

REGULATION OF AMPLIFICATION DURING PRODUCTION TESTING Scanning sensitivity shall be as provided in API 1104 para 11.4.7.2 &11.4.7.3.

1.10 QUALIFICATION OF ULTRASONIC TESTING OPERATORS

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 22 of 52

Copyright GAIL – All rights reserved

Before the actual inspection begins, the COMPANY may require a qualification test for the ultrasonic equipment operators. 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 operators shall be able to: a)

Calibrate the equipment

b)

Perform an operational test under production conditions

c)

Interpret the screen picture

d)

Evaluate the size and location of reflectors

e)

Interpret the type of defects detected.

The COMPANY has the option of checking the ability of personnel employed for Ultrasonic testing by means of qualification tests. 1.11 EVALUATION OF INDICATIONS GIVEN BY ULTRASONIC TESTING Each time that echoes from the instrument amplification shall amplifications and the probe obtained, paying attention all the

weld bead appear during production testing, the be altered to coincide with the reference shall be moved until maximum response is 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. 1.12 OTHER EQUIPMENT The use of rules calibrated in centimeters, attached to the probe is recommended for the precise location of the position of welding defects. Defect location is effected by measuring the projection distance between the probe output and the reflecting surface.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 23 of 52

Copyright GAIL – All rights reserved

The operators carrying out the tests may require other equipment besides the probing instrument, tools for cleaning the pipe surface viz. files, brushes etc., and coupling liquid or paste appropriate for the temperature of the section to b examined.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 24 of 52

Copyright GAIL – All rights reserved

ANNEXURE – 3 AUTOMATED ULTRASONIC TESTING (AUT) 1.0

INTRODUCTION

2.0

REFERENCE DOCUMENTS

3.0

APPROVED AGENCIES

4.0

AUT SYSTEM

5.0

COUPLING

6.0

SEARCH UNITS

7.0

CALIBRATIONS

8.0

PROCEDURE

9.0

TRAINING AND QUALIFICATION

10.0

FIELD EXAMINATIONS AND REPORTING

11.0

INTERPRETATION OF RESULTS

12.0

ACCEPTANCE CRITERIA

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 25 of 52

Copyright GAIL – All rights reserved

1.0

INTRODUCTION 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.

2.0

REFERENCE DOCUMENTS ASTM E 1961-98 “Standard Practice for Mechanized Ultrasonic examination of Girth Welds using Zonal Discrimination with Focused Search Units”. The inspection system shall meet and exceed the requirements of ASTM E 1961-98. Appendix-E, “Automated Ultrasonic Girth Weld Testing”, OS-F101, Submarine Pipeline Systems, January 2000. API Std. 1104 – “Welding of Pipeline and Related Facilities”.

3.0

APPROVED AGENCIES 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.

4.0

AUT SYSTEM The system shall meet and exceed the requirements of ASTM E1961-98. The system shall provide an adequate number of examination channels to ensure the complete volumetric examination of the weld through the thickness in one circumferential scan. The evaluation zones should be of maximum 2.0mm height. The instrument linearity should be such that the accuracy is within 5%. Each examination channel should be selective for pulse-echo or through transmission mode gate position and length for a minimum of two gates and gain. TOFD techniques & B-scan mapping should be available to improve characterization. Recording thresholds should be selectable to display signals between 0 and 100% of full screen height for simple amplitude and transit time recording and it should be from 0 to 100% for B-scan or mapping type recording of data. Two recordable signals output per gate should be available being either analog or digital and representative of signal height and time of flight. Measuring distance accuracy of circumferential weld shall be within 1.0 cm from zero (0) position. GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 26 of 52

Copyright GAIL – All rights reserved

Electronic noise shall be lower than acoustical noise in all channels for the probes and sensitivities to be used during inspection. The signal to noise ratio for each channel during examination shall be at least ≥ 20 dB for shear waved probes. 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.

6.0

SEARCH UNITS The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961- 98.

7.0

CALIBRATIONS Reference standards shall be manufactured from a section of unflawed project specific line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the reference standard design to the COMPANY before manufacturing. No design changes in the reference standard shall be made without the prior approval. Annexure A3 of the standard ASTM E1961-98 provides an example for minimum requirements for reference standards. 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 re-calibration shall be carried out if: a) b)

The calibration of an inspection function differs more than +/- 3dB from the previous calibration 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 27 of 52

Copyright GAIL – All rights reserved

The reference standard design for calibration shall be approved separately. The procedure for calibration and verification shall be same as given above. 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: - Functional description of equipment - Reference standards and guidelines controlling equipment maintenance - Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics, Hard & Software for recording processing, Display presentation and storage of inspection data - Transducer configuration(s), characteristics types coverage. - Number of examination zones for each wall thickness to be examined. - Gate settings - Equipment settings - Description of calibration blocks including type, size and location of calibration reflectors, a) calibration intervals, b) calibration records - Static and dynamic calibration procedure - Identification of inspection starting point scanning direction and indication of length inspected - Method for scanner alignment and maintenance of alignment - Allowed temperature range - Couplant coupling and coupling control and channels provided to indicate lack of coupling and method to ensure constant coupling - Transducer and over all functional checks - Height and length sizing methodology - Surface condition and preparation - Description of inspection work - Acceptance criteria and instructions for reporting including example of recorder chart and form to be used. - A table indicating corresponding channel no., probe, type, location of reflector, probe coupling etc.

8.1

Setting of Inspection Gates

8.1.1 Pulse-echo and Tandem Channels 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 28 of 52

Copyright GAIL – All rights reserved

The length of the transit distance in the root channel will be extended root penetration registration.

to

enable

8.1.2 Mapping Channels 8.1.3 The mapping gates in the body of the weld shall start 2-6mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate length will be extended to enable cap reinforcement registration. The mapping gates in the root will be set identical to the pulse-echo transit distance channels to enable the registration of the root penetration. 8.1.4 TOFD Channel 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. Note: The gate settings may be altered if geometry indications dictate. 8.1.5 Sensitivity Settings 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. 9.0

TRAINING AND QUALIFICATION

1.

All Inspectors’ of the COMPANY (Owner) shall be imparted training at the CONTRACTOR’s cost. The inspector shall be provided complete awareness and knowledge regarding the equipment, limitations, capabilities complete range, method of operation, calibration, scanning, including development of suitable procedure, training on variables effecting the system performance and interpretation of results.

2.

The Ultrasonic lead operator performing the examination shall be qualified in accordance with the COMPANY’s written practice and in accordance with ASNT Practice SNT-TC-1A and EN 473 Level II. He should have experience in multichannel UT equipment and be trained in using mechanized UT manipulators.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 29 of 52

Copyright GAIL – All rights reserved

10.0

FIELD EXAMINATIONS AND REPORTING All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a minimum.

11.0 INTERPRETATION OF RESULTS 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.

11.2

Inspection Result The inspection result should be evaluated and/or reported as follows: 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. 2.

3.

4.

All indications in the pulse echo channels should be evaluated which exceed the threshold level of 20% FSH. 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. 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. 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.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 30 of 52

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.

12.0 ACCEPTANCE CRITERIA Weld quality shall be judged on the basis of the acceptability criteria mentioned in Para 12.5.1 of welding specification.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 31 of 52

Copyright GAIL – All rights reserved

1.0

SCOPE

ANNEXURE-4 (RADIOGRAPHY TESTING)

This annexure covers the Radiography Testing of all types of welded joints of the main pipeline. The welded joints shall include the following: i) Full girth welds on the mainline construction including double jointing of pipe, if adopted. ii) Welds for installation of block valves, insulating joints and other appurtenances and tie-ins. iii) Welds at scraper launching and receiving barrels. iv) Terminal Piping. 2.0

APPLICABLE STANDARDS This specification shall apply in conjunction with the following (all latest editions): i) API 1104, Standard for welding Pipelines and Related Facilities ii) ANSI B 31.8, Code for Gas Transmission and Distribution Piping Systems. iii) ANSI B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols. iv) ASTM E 94, Recommended practice for Radiographic Testing v) ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing v) The American Society for Nondestructive Testing. Recommended Practice No. SNT-TC 1A Supplement A.

3.0

PROCEDURE

3.1

The Radiography examination procedure to be adopted shall be submitted by the CONTRACTOR as per Exhibit - F.

3.2

The procedure of Radiography examination shall be qualified to the entire satisfaction of COMPANY prior to use. It shall include but not be limited to the following requirements: i)

Lead foil intensifying screens, at the rear of the film shall be used for all exposures.

iii)

Type 2 and 3 films as per ASTM E-94 shall be used.

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.

v)

Radiography identification system and documentation for Radiography interpretation reports and their recording system.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 32 of 52

Copyright GAIL – All rights reserved

3.3

The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior to use.

3.4

The procedure of Radiography examination shall produce radiographs of sufficient density, clarity and contrast so that defects in the weld or in the pipe adjacent to the weld are clearly discernible.

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.

3.10

Each day's production of processed radiographs shall be properly packaged separately, identified by (1) date, (2) radiography unit, (3) job locations, (4) starting and ending progress survey stations, and (5) shall include original and three (3) copies of the daily radiography record. The package shall be submitted to the COMPANY daily when possible, but in no event later than noon of the following day.

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. GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 33 of 52

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.

4.0

RADIATION SOURCE

4.1

Radiography examination shall be carried out using X-radiations. Radiography examination by Gamma rays using slow speed films may be allowed, at the discretion of the COMPANY in case of inaccessible joints. Radiography by Gamma ray for tie-in-joints shall be acceptable provided D4 AGFA film or equivalent is used and the required sensitivity obtained.

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.

5.0

LEVEL OF QUALITY The quality level of Radiography sensitivity required for Radiography inspection shall be at least equivalent to the values in FIG.5.

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

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 34 of 52

Copyright GAIL – All rights reserved

the outline of the IQI, its identification number and the wire of the required diameter show up clearly on the radiograph. 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. 2.0

FILM IDENTIFICATION MARKERS 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.

8.0

PROTECTION AND CARE OF FILM

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. 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.

9.4

10.0 QUALIFICATION OF RADIOGRAPHERS

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 35 of 52

Copyright GAIL – All rights reserved

10.1

Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and to the full satisfaction of 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: i) Background and Experience Record ii) Training Course Record iii) Technical Examination Record iv) Doctor's report on radiographer's Jacque 0-1 acquity eye test v) Date of qualification

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.

11.0

PRESERVATION OF RADIOGRAPHS

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.

11.2

All radiographs shall become property of the COMPANY.

12.0 EQUIPMENT AND ACCESSORIES 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.

13.0 RADIATION PROTECTION 13.1 13.2 13.3

CONTRACTOR shall be responsible for the protection and personnel monitoring of every man with or near radiation sources. The protection and monitoring shall comply with local regulations. In view of visual hazards in the handling of Radioactive source of material, CONTRACTOR shall be solely responsible for complying with all rules and regulations set forth by Atomic Energy Commission or any other Government GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 36 of 52

Copyright GAIL – All rights reserved

agencies of India in this regard and COMPANY shall not be responsible and shall be kept indemnified by the CONTRACTOR for default (s) of whatever nature by the CONTRACTOR. Safety equipment as considered adequate by the COMPANY for all necessary personnel shall be made available for use and maintained for immediate and proper use by the CONTRACTOR. 14.0

DISPLAY OF SAFETY INSTRUCTIONS

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.

15.0 ENFORCEMENT OF SAFETY REGULATIONS 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.

16.0 FIRST AID AND INDUSTRIAL INJURIES 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 Notwithstanding the above there is nothing in these to exempt the CONTRACTORN from the operation of any other act or rules in force.

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 37 of 52

Copyright GAIL – All rights reserved

Sheet – 1 of 3 EXHIBIT- A A:

B

(ELECTRODE QUALIFICATION TEST RECORD)

Tested at (Site name) Date: Manufacturer’s Name Brand Name Batch Number & Size tested Classification & Code Intended for welding in position : In combination with (if any) Code of Reference (used for testing) Special Requirements (if any) All-weld Tensile Test Base Material used Pre-heat temperature Post weld heat treatment details Visual examination Radiographic examination results Tensile test results

GAIL (INDIA) LTD NEW DELHI

: : : : : : :

: : : : : :

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 38 of 52

Copyright GAIL – All rights reserved

EXHIBIT – A (CONTD.) Sheet 2 of 3 C.

D.

Impact Test Results Test Temperature :

Notch in :

Type of Specimens (Charpy) :

Size of Specimens :

Chemical Analysis Results Electrode Size Result : Batch No. :

E.

Fillet Weld Test Results : Welding Positions : Base Materials : Size of electrode used : Visual Inspection Results : (1) (2) (3)

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 39 of 52

Copyright GAIL – All rights reserved

EXHIBIT – A (CONTD.) Sheet 3 of 3 Macro Test Results

:

Fracture Test Results

:

Remarks

:

F.

Other Test Results

:

1.

Transverse tensile test : In combination with

:

Base material used

:

Position of welding

:

Preheat temperature

:

Post weld heat treatment

:

Radiography

:

Identification No. U.T.S. Fracture in Remarks 2.

Guided Bend Test

:

G. Any other tests :

H. Conclusions :

--------------------PREPARED BY (CONTRACTOR)

GAIL (INDIA) LTD NEW DELHI

-------------------REVIEWED BY (CONTRACTOR)

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

------------------------APPROVED BY (OWNER)

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 40 of 52

Copyright GAIL – All rights reserved

Sheet – 1 of 1 EXHIBIT - B (STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION) Name of the Heat-Treater : Name of the Project : Specification Reference No. : 1.

General Detail : 2. Furnace Details : Name of the Equipment : Type of Heating : Gas/Oil/Elect. Name of the Assembly/Part : Res./Induction Type of Heating : Drawing No : Capacity (Size) : Material : Maximum Temp.( °C) : Method of temp. Measurement : Atmosphere Control :

3.

Heat Treatment Cycle Details : Charging Temp. (°C) : Rate of heating, (°C)/Hr : Soaking Temp. (°C) : Soaking Time, (Hrs.) : Rate of Cooling, (°C)/Hr : Mode of Cooling :

4.

Other Details, if any : Notes : The following documents shall be furnished along with the specifications: i) Material test certificates

ii) Assembly/Part Drawing

--------------------PREPARED BY (CONTRACTOR)

GAIL (INDIA) LTD NEW DELHI

-------------------REVIEWED BY (CONTRACTOR)

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

------------------------APPROVED BY (OWNER)

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 41 of 52

Copyright GAIL – All rights reserved

EXHIBIT - C (FORM FOR WELDING PROCEDURE QUALIFICATION TEST RECORD) Sheet – 1 of 3

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 42 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 43 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 44 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 45 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 46 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 47 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 48 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 49 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 50 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 51 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 52 of 52

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION CHARTS FOR PIPE WELDING- A1A, B1A, D1A, A3A

SPECIFICATION 0001-01-04-02-001-WSC1

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

JOB SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPUR LINES OF CHAINSA-JHAJJAR PIPELINE

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

REV-0 Page 1 of 6

Copyright GAIL – All rights reserved

TABLE OF CONTENTS

1.0

SCOPE

2.0

DESIGN

3.0

MATERIAL

4.0

DELIVERY, STORAGE, HANDLING

5.0

MARKING

6.0

OTHER TECHNICAL REQUIREMENTS

7.0

INSTALLATION

9.0

DOCUMENTATION

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

REV-0 Page 2 of 6

Copyright GAIL – All rights reserved

1.0 SCOPE 1.1

This specification covers the minimum requirements for design, manufacture and supply of non-biodegradable geo-textile bags (made from polypropylene fabric) intended to be used for providing anti-buoyancy measures when filled with Gravel/stone ballast materials.

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

2.3

The geo-textile bags shall meet the following requirements: 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.

b.

Geo-textile bags shall be of top loading fabric-type made from woven polypropylene material.

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.

2.7

Repair of bags, in any manner is not permitted.

3.0 MATERIAL GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

REV-0 Page 3 of 6

Copyright GAIL – All rights reserved

3.1

The body fabric must be treated for UV protection and longevity. The weight of the 2

body fabric must be a minimum of 400 gms/m . 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.

3.5

All testing should be as per ASTM or equivalent standards

4.0 DELIVERY, STORAGE AND HANDLING 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. b.

Product model Name of Manufacturer

c.

Dimensions of bag in mm.

d.

Weight carrying capacity (Total weight when filled)

e.

Year, month of manufacture and product batch number

6.0 OTHER TECHNICAL REQUIREMENTS GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

REV-0 Page 4 of 6

Copyright GAIL – All rights reserved

6.1

Manufacturer shall provide skilled persons for initial assistance / on the job training during filling and installation of supplied geo-textile bags till the pipeline installation contractor will get trained in filling & installation to the satisfaction of Engineer In charge

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. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

REV-0 Page 5 of 6

Copyright GAIL – All rights reserved

8.5

Complete descriptive technical catalogues describing the materials offered along with samples of geo-textile bags, its properties, testing results and installation instruction as applicable specifically to the project, Specific storage and handling instructions.

8.6

Manufacturer shall highlight any precautions / safety measures to be taken.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

REV-0 Page 6 of 6

Copyright GAIL – All rights reserved

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING SPUR LINES OF CHAINSA-JHAJJAR PIPELINE

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 1 of 15

Copyright GAIL – All rights reserved

TABLE OF CONTENTS 1.0

INTRODUCTION

2.0

RESPONSIBILITY OF CONTRACTOR

3.0

SCOPE OF WORK 3.1

Precommissioning activities

3.2

Commissioning related activities

4.0

DOCUMENTATION

5.0

SPARES AND COMSUMABLES

6.0

SAFETY

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 2 of 15

Copyright GAIL – All rights reserved

1.0 INTRODUCTION This specification covers the minimum technical requirements for: i.) Precommissioning of : Sl.

Pipeline

Tap-off Point

Size(Inch) X Length (Km)

1

Sultanpur Haryana) to Neemrana (Rajasthan)

Tap-off point at Chainage – 70.05 Km in Chainsa-Jhajjar line

18” X 85.28

2

Spur Line to Bhiwadi

Tap-off point at Chainage – 12” X 9 31.6 Km in Sultanpur – Neemrana Line

3

Hayatpur to Manesar

Tap-off point at Chainage – 61.14 Km in Chainsa-Jhajjar line

4

Hayatpur to Gurgaon

Tap-off point at Chainage – 10” X 11 61.14 Km in Chainsa-Jhajjar line

10” X 5.4

ii.) Commissioning activities consisting of Drying, Inertisation, Gas-in / Commissioning, stabilization and 72 hours run of Pipeline as mentioned above in Table 1.0 - ( i ) Contractor, along with his bid documents, is required to submit the following: •

Execution plan and method statement for pre-commissioning and commissioning activities.



Past experience of pre-commissioning and commissioning activities carried out for a similar pipeline system / network.



Plan to engage an agency / subcontractor for these activities (if envisaged).



Organization charts of bidder’s proposed pre-commissioning and commissioning team indicating the positions with the required qualifications and experience.



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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 3 of 15

Copyright GAIL – All rights reserved

absence of this, it shall be considered that the bidder has no deviation. 

2.0

Questionnaire as given in Appendix-I duly filled by bidder.

RESPONSIBILITY OF CONTRACTOR The contractor shall be responsible for all the pre-commissioning and commissioning activities that need to be carried out for the pipeline system.

2.1

Precommissioning In order to execute and perform pre-commissioning activities, the contractor shall be responsible for (but not limited to): •

Carrying out precommissioning checks of the underground pipeline system including above ground piping at dispatch station and at receipt stations, Sectionalising Valve (SV) stations, CGS/ PRS Station, tap-off / hook-up piping and all terminals.



Dewatering of the pipeline.



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.



Supply and supervision of manpower for precommissioning.



Supply and operation of machinery & equipment for precommissioning.



Supply and use of materials precommissioning activities.



Design and supply all temporary line connections, pig launcher/receiver, valves, instruments, manpower etc. as required during various operations.



Preparation of detailed precommissioning procedures, activity schedules, bar charts, schemes etc.



This shall include preparation of detailed procedures for dewatering, flushing, swabbing, and low pressure leak check and shall address the sequence and

GAIL (INDIA) LTD NEW DELHI

and

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

consumables

as

required

SPECIFICATION 0001-01-04-02-003

for

the

REV-0 Page 4 of 15

Copyright GAIL – All rights reserved

methodology describing all operations, data on materials, equipment, instruments, consumables, communication systems, necessary calculations, detailed time schedule and organization chart. 

All necessary work to perform the job successfully including all modifications that would be required. 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.

2.2

Drying, Inertisation, Gas-in / Commissioning, stabilization and 72 hours run In order to execute and perform commissioning related activities, the contractor shall be responsible for (but not limited to): 

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.



Commissioning checks including Safety review prior to start of commissioning activities to achieve ‘Ready for commissioning’ status for underground pipeline and above ground piping system at dispatch and receipt stations, above ground piping system at IP stations, SV stations and hook-up / tap-off points.



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.



Stabilization and 72 hours run of the pipeline system.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 5 of 15

Copyright GAIL – All rights reserved

3.0



Supply and supervision of manpower for commissioning.



Supply and operation of machinery & equipment for commissioning.



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.



Preparation of detailed commissioning procedures, activity schedules, bar charts, schemes etc.



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.

SCOPE OF WORK The work to be performed by the Contractor as part of the precommissioning activities for the facilities outlined in paragraphs and Table (i) of Section-1.0 above and commissioning related activities for the facilities outlined in paragraphs (ii) of Section-1.0 above shall consist of the following:

3.1

Precommissioning activities

3.1.1 Precommissioning checks GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 6 of 15

Copyright GAIL – All rights reserved

Pre-commissioning checks shall be carried out for the pipeline system to ascertain that the pipeline system has been mechanically completed in all respects. These checks shall cover the main pipeline including distribution network system, dispatch and receipt stations, all Terminal Stations, CGS/ PRS stations, sectionalizing valve stations and the hook up points. The pre-commissioning checks shall include the following: 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. B) Checking of Field Instruments 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. C) Survey of the Pipelines This shall be performed to confirm that proper fittings/supports, Cathodic protection system, route markets, warning signs, fencing around SV stations, crash barriers etc. have been installed along the pipeline. D) Checking of Communication System This is to check that there is proper communication with adequate back-up power to ensure uninterrupted communication. E) Checking of Electrical Distribution System This is to ensure safety and also to ensure an uninterrupted power supply during startup and normal pipeline operation. F) Checking of Instruments, Controls & Interlocks This is to check that instrument controls and interlocks are functional as per the normal operating conditions.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 7 of 15

Copyright GAIL – All rights reserved

G) Checking of Utilities This is to check that utilities like power, nitrogen, UPS system, instrument air, etc. are available prior to start-up. H) Any other checks as may be considered necessary. 3.1.2 Dewatering 3.1.2.1 General Dewatering of a pipeline section shall be done subsequent to the hydro-test of the respective pipeline section. During the dewatering operation, the major quantity of hydro-test water shall be removed from the main pipelines and distribution network. It is the responsibility of the contractor to develop suitable dewatering procedure and submit the same for Company's approval. 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. 3.1.2.2 Operational requirements 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. Flushing of aboveground piping

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 8 of 15

Copyright GAIL – All rights reserved

Flushing of above ground piping at dispatch and receipt stations, SV stations, hook-up / tap-off points and IP stations shall be done with water to remove debris from within the piping and then with dry air to remove the residual amount of water from the aboveground piping. 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 swabbing operation, which shall be done subsequent to the dewatering operation, is meant to reduce the remaining water in the pipeline to acceptable condition and to ensure removal of free water left inside the pipeline prior to final drying, Inertisation and commissioning of the Pipeline system. This is done by driving number of foam pigs propelled by oil free compressed dry air, which can pick up free water in the pipeline. Hence for swabbing, air compressors of required capacity, after-coolers and dryers should be deployed by the contractor. Contractor may suggest alternate methodology for Swabbing operation. The swabbing activity is precursor for drying of the pipeline and is basically to reduce duration of drying. The contractor shall submit the detailed procedure and the duration of the swabbing operation and obtain approval of the company before starting the operation. 3.1.3.2 Acceptance criteria The Contractor shall ensure that swabbing operation is considered to be completed when it is considered that there is no free water left in the pipeline.This shall be subject to Company’s approval. 3.2 Commissioning related activities

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

REV-0 Page 9 of 15

Copyright GAIL – All rights reserved

3.2.1 Drying 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. Commissioning contractor shall assess any requirement of swabbing for entire pipeline to reduce the time for drying and shall carryout such activity. 3.2.1.2 Acceptance criteria 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 Low Pressure leak check for aboveground piping

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. 3.2.2.2 Acceptance criteria

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION

REV-0

0001-01-04-02-003

Page 10 of 15

Copyright GAIL – All rights reserved

The leak check operation shall be considered to be completed when the piping 2

system / equipment is free of leaks when tested at a pressure of 6.0 Kg/cm g. This shall be subject to Company’s approval. 3.2.3 Ready for Commissioning After completion of drying activities and safety review prior to startup, Contractor shall notify the Company that the systems associated with the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, al Terminal Station, CGS/ PRS stations and hook-up / tap-of points are ready for gas-in/commissioning. 'Ready for commissioning status' shall be jointly reviewed by Company and Contractor and final clearance for start-up shall be given by the Company. After such joint assessment, if all the criteria are met, it will then be declared that the pipeline system has reached a stage of 'Ready for Commissioning'. 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). 3.2.4.2 Operational requirements 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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION

REV-0

0001-01-04-02-003

Page 11 of 15

Copyright GAIL – All rights reserved

For above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points, the piping shall be purged with nitrogen till the residual oxygen content in the piping is below 1% (vol/vol). 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. 3.2.4.3 Acceptance Criteria 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 / tapof points, the inertisation may be accepted to be complete when the residual oxygen content in the piping is below 1% (vol/vol). 3.2.5 Safety review prior to start of Commissioning activities A pre-startup safety review of the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal stations, CGS/ PRS stations and hook-up / tap-of points shall be carried out by the Contractor before permitting entry of natural gas into the new pipeline facility. Company / Company's representative shall also participate in the pre-startup safety review. 3.2.6 Gas-in/Commissioning and Stabilization 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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION

REV-0

0001-01-04-02-003

Page 12 of 15

Copyright GAIL – All rights reserved

3.2.6.2 Operational requirements 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. 3.2.6.3 Acceptance Criteria The system shall be considered to be commissioned successfully when 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 is charged with natural gas, is free of leaks and run successfully at stable operating conditions with instrumentation / control systems process utilities and support systems taken on line for a minimum period of 72 hours. The commissioning of pipeline system shall include commissioning of branch lines and associated facilities including auxiliary facilities and aboveground piping.

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION

REV-0

0001-01-04-02-003

Page 13 of 15

Copyright GAIL – All rights reserved

• • • • •

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. 5.0

SPARES AND CONSUMABLES Contractor shall identify and arrange for supply of manpower, spares, tools, tackles and consumables as required for pre-commissioning and commissioning activities.

6.0

SAFETY Contractor shall follow the safety practices during execution of precommissioning 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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION

REV-0

0001-01-04-02-003

Page 14 of 15

Copyright GAIL – All rights reserved

APPENDIX-I QUESTIONNAIRE {PRIVATE }CLAUSE DESCRIPTION OF CLAUSE NO.

AGREED

NOT REMARKS AGREED

1.0

SCOPE

[ ]

[ ]

2.0

DEFINITIONS

[ ]

[ ]

3.0

MANUFACTURER REPRESENTATIVE

[ ]

[ ]

4.0

DOCUMENT FOR PRECOMMISSIONING AND COMMISSIONING

[ ]

[ ]

5.0

OTHER REQUIREMENTS

[ ]

[ ]

6.0

REVIEW/CHECKLISTING/INSPECTION/COORDINATION

[ ]

[ ]

7.0

COMMISSIONING

[ ]

[ ]

8.0

CONSUMABLES

[ ]

[ ]

9.0

SPECIAL REQUIREMENTS

[ ]

[ ]

10.0

SAFETY

[ ]

[ ]

NOTE: 1) 2)

PLEASE TICK THE RELEVANT BOX. MENTION THE REASON & THE SUB-CLAUSE NOT AGREED IN THE REMARKS COLUMN.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION

REV-0

0001-01-04-02-003

Page 15 of 15

Copyright GAIL – All rights reserved

STANDARD SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDED (LSAW) LINE PIPE (ONSHORE)

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 1 of 36

Copyright GAIL – All rights reserved

Abbreviations: ASTM

American Society for Testing and Materials

API

American Petroleum Institute

ID

Inside Diameter

LSAW

Longitudinal Seam Submerged Arc Welded

HAZ

Heat Affected Zone

NDT

Non Destructive Testing

NPS

Nominal Pipe Size

OD

Outside Diameter, Specified

WT

Wall Thickness, Specified

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 2 of 36

Copyright GAIL – All rights reserved

CONTENTS 1

SCOPE

2

REFERENCES

5

PROCESS OF MANUFACTURE AND MATERIAL

6

MATERIAL REQUIREMENTS

7

DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

9

INSPECTION AND TESTING

10

MARKING

11

COATING AND PROTECTION

12

DOCUMENTS

14 (New)

INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-B

REPAIR OF DEFECTS BY WELDING (NORMATIVE)

APPENDIX-C

REPAIR WELDING PROCEDURE (NORMATIVE)

APPENDIX-F

SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR 5

FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4½ OR LARGER

SR 6

DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER.

SR 19

ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE

APPENDIX-H

PURCHASER INSPECTION (NORMATIVE)

APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)

ANNEXURE-I

MANUFACTURING PROCEDURE SPECIFICATION

(New) ANNEXURE-II

FIRST DAY PRODUCTION TESTS

(New) ANNEXURE-III

INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING

(New) FIGURE 6.2.6.1

METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

FIGURE 6.2.6.2

LOCATIONS FOR HARDNESS MEASUREMENT

FIGURE 7.8.3

PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD

FIGURE9.8.5.2

REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 3 of 36

Copyright GAIL – All rights reserved

1.0

SCOPE

1.1

PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinal 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/ Supplements 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 as that of API Spec 5L in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of Specification 5L, Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2.

1.2

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL 2.

1.3

GRADES This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

DIMENSIONS This specification shall be applied to line pipe of size 16” through 48” (both sizes included)

2.0

References

2.1

The latest editions (edition enforces at the time of issue of enquiry) of following additional references are included in this specification: ASTM ASTM E 92

: Test Method for Vickers Hardness of Metallic Materials.

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.

ASME IX ASME B31.8

: Boiler & Pressure Vessel code: Welding & brazing quality. : Gas Transmission & Distribution piping system.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 4 of 36

Copyright GAIL – All rights reserved

OISD – 141 API RP 5 L1

: Oil Industries safety distribution piping system : Recommended practice for railroad transmission of line pipe

5.0

Process of Manufacture and Material

5.1

PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification:

5.2

Welding Process

:

Submerged Arc Welding as per para 5.1.2.2.1

Type of Pipe per para 5.1.3.5

:

Longitudinal Seam Submerged Arc Welded Pipe as

Type of Seam Weld para 5.1.4.3

:

Submerged Arc Weld (Longitudinal Seam) as per

COLD EXPANSION All pipes shall be mechanically cold expanded for full length. The expansion measured on the circumference shall range between 0.8 to 1.5% of the value measured before the expansion. The expansion shall be measured and recorded for one out of every 50 pipes.

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.

5.4

HEAT TREATMENT The pipes shall be produced from plates/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.

6.0

Material Requirements

61

CHEMICAL PROPERTIES

6.1.1 Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 5 of 36

Copyright GAIL – All rights reserved

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

1.60

max. (For Grade X56 to X70)

0.15

min.

Si

0.45

to X52)

max.

S

0.015

max.

P

0.02

max.

Al

0.07

max.

Nb

0.05

max.

V

0.08

max.

Ti

0.04

max. (For Grade B

0.06

toX60)

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.

Note: g (New) i.

V+Nb+Ti shall not exceed 0.1 5%

ii.

Cu-+-Ni shall not exceed 0.40%

iii.

Al/N shall be min. 2

Note: h (New) If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i(New) Minimum for Si is not applicable for Al killed steel.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 6 of 36

Copyright GAIL – All rights reserved

6.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analysed and reported, even if those are not purposely added but are present as residuals only. 6.1.3

Carbon Equivalent (PSL 2 Only)

6.1.3.1

Calculation of Carbon Equivalent

Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 6.1.3.2

Maximum Carbon Equivalent

For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits:

6.2

CE (Pcm )

‫ﮐ‬

0.20 %

CE (IIW )

‫ﮐ‬

0.40 %

MECHANICAL PROPERTIES

6.2.1 Tensile Properties The finished pipe (after all heat treatment and expansion or sizing operations) shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under; API Spec 5L Grade Up to and including X46

Permissible in excess of SMYS. Psi (MPa) 19,000 (131)

X52 TO X65

22,000(152)

X70 and Above

20.000 (138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal of finished expanded 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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 7 of 36

Copyright GAIL – All rights reserved

API Spec 5L. Appendix D. However elongation in no case shall be less than 20%. API Spec 5L, Appendix D stands modified accordingly. 6.2.5

Fracture Toughness Tests

6.2.5.2

Charpy Impact Tests for PSL 2

For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. 6.2.5.3

Supplementary Fracture Toughness Tests

For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area in accordance with Supplementary Requirement SR 5A of API Spec 5L and as modified in this specification shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order. Drop Weight Tear Test in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size, grade and wall thickness. 6.2.6

Metallographic Examination

6.2.6.1 A test specimen for metallographic & hardness examination shall be taken transverse to the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) whichever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen extraction shall be as per Fig. 6.2.6. 1 of this specification. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that proper fusion has been obtained for the full thickness, and there is proper interpretation of passes, their alignment and texture of weld zone. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's Representative. 6.2.6.2 Vickers hardness tests shall be carried out on each specimen taken for metallographic 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 value at any point shall not exceed 248 HV10, Modalities of re-test shall be in accordance with para 9.12.2 of API Spec. 5L. 7

Dimensions, Weights, Lengths, Defects and End Finishes

7.2

DIAMETER Pipe Body

The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6C, Appendix E. API GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 8 of 36

Copyright GAIL – All rights reserved

Spec 5L Table 7 stands modified accordingly. Size

Tolerances

≥16 and < 20

± 3 mm

≥20 and ≤36

+ 3 mm, 0.25% of specified OD

>36

± 3 mm.

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

< 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).

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 9 of 36

Copyright GAIL – All rights reserved

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. 7.6

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 Jointers on pipes are not permitted.

7.8

WORKMANSHIP AND DEFECTS

7.8.1

Dents

Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable. 7.8.2

Offset of Plate Edges

All pipes shall be checked for offset of plate/ skelp edges. Offset shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.8.3

Out-of-Line Weld Bead for Pipe with Filler Metal Welds

A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment shall be measured on radiographic film and calculated using the formula (a+b)/2 where 'a’ and 'b' are the relative offsets of the outside edges of the seam (refer Figure 7.8.3 of this specification). All pipes shall be checked for out-of-line weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out on metallographic examination specimen as stated at para 6.2.6, 7.8.4

Height of Outside and Inside Weld Beads - Submerged Arc Welds

The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height using a template having a cut out for weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum). GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 10 of 36

Copyright GAIL – All rights reserved

7.8.8

Hard Spots

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. 7.8.9

Cracks, Sweats and Leaks

Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the requirement of API Spec 5L para 9.9 (c) or (d). 7.8.10

Laminations

Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of detects on the plate/skelp shall be as per para 9.8.5.4 of this specification. 7.8.12

Undercuts

Undercutting not classified as minor shall be considered a defect. Disposition shall he as follows: 1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12 ½ % 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 12 ½ % of the specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d). 7.8.14 Other Defects Any imperfection (measured from the surface) with a depth greater than 5% of the specified wall thickness of the pipe shall be considered a defect and shall be repaired in accordance with para 9.9 and as modified in this specification. 7.8. 15 Peaking (New)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 with these requirements shall be disposed off as per API Spec. 5L para 9.9 (c) or (d). 7.9

PIPE ENDS

7.9.1

General Pipes shall be furnished with plain ends.

7.9.3

Plain Ends 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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 11 of 36

Copyright GAIL – All rights reserved

and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall be rebevelled and rectification by filing or grinding shall not be done. 7.9.6 Bevel Protectors (New) 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 he re-used by coating applicator for providing on externally anti-corrosion coated pipes subsequent to coating of line pipe. 9.0

Inspection and Testing

9.2

TESTING OF CHEMICAL COMPOSITION

9.2 1 Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production. 9.2.2 Product Analysis 9.2.2.1 Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat are also represented. 9.2.2.2 Sampling Method 9.2.2.2.2 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from plate/skelp may be used provided the traceability of samples is guaranteed. 9.3

TESTING OF MECHANICAL PROPERTIES

9.3.1

Tensile Tests

Tensile property shall be determined from specimen removed from pipe which has been subjected to all mechanical operations. 9.3.1.2 Tensile Testing Frequency Tensile tests shall be made at the frequency of one test per inspection lot as shown in Table 13, except as modified below: . Table 13: Maximum Inspection Lot Size for Tensile Testing For Size 12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13 shall also be applicable.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 12 of 36

Copyright GAIL – All rights reserved

9.3.1.4

Transverse Tensile Tests

The transverse tensile tests shall be carried out on flattened rectangular specimen. 9.3.1.5

Weld Tensile Tests

Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first day production test as specified in Annexure-II of this specification to determine the yield strength, ultimate tensile strength and elongation. The cylindrical all weld specimen shall have gauge length, L = 5d, where; L = gauge length (mm) D = diameter of the test specimen (mm) The results of the test shall meet the minimum requirements of the plate/skelp with regard to yield, tensile and elongation parameter. 9.3.5

Fracture Toughness Tests

9.3.5.1

Charpy Test Specimens

In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with heat affected zone (HAZ) in the middle shall also be taken. 9.3.5.2

Charpy Testing Frequency

The minimum test frequency shall he one test (a set of three specimen each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. 9.4

HYDROSTATIC TESTS

9.4.1

Hydrostatic Test Requirements

Hydro test shall be carried out after cold expansion. Test pressure shall be held for a minimum period of I5 seconds for all sizes and grades of pipes. 9.4.2 Verification of Hydrostatic Teat 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 record shall be maintained. Calibration record shall be GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 13 of 36

Copyright GAIL – All rights reserved

furnished to the purchaser’s representative on request. 9.4.3

Test Pressure

The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5L para 9.4.3 (Note 2). 9.4.5

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. DIMENSIONAL TESTING

9.5

The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request. 9.7

VISUAL INSPECTION

All pipes shall be visually examined both externally and internally (to the extent feasible) and shall be free of defects in the finished condition. NON DESTRUCTIVE INSPECTION

9.8

The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice, plant access, compliance and rejection mentioned in Appendix H of API Spec 5L. The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in strict accordance with this specification. 9.8.1

Qualification of Personnel

All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. Inspector Qualification GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 14 of 36

Copyright GAIL – All rights reserved

Acceptable qualification for NDT inspectors shall be as specified below: 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 all other NDT methods Evaluation of indications :

Level I, II, III inspector

Supervision

Level II or Level III inspector (in case evaluation is by Level I inspector)

9.8.3

:

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of weld seam of cold expanded pipe shall be performed after cold expansion and hydrotesting. 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 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 plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination, the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Pipe 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 technique over a circumferential width of at least 50 mm to detect surface cracks. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table 24) using

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 15 of 36

Copyright GAIL – All rights reserved

automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be re-examined by radiography. If during production, repeated ultrasonic indications occur requiring re-inspection by radiography and it appears from radiographs that the nature of defects causing the ultrasonic indications cannot be definitely established, the Manufacturer shall prove by other inspection methods (e.g. by making some cross-sections in accordance with para 6.2.6 of this specification at locations where such indications occur near the end of the pipe) to the satisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 9.8.3.1

Pipe End Weld Inspection

Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged-arc weld seam shall be radiographically examined for a minimum distance of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be recorded. 9.8.4

Radiological Inspection-Weld Seams

9.8.4.1

Radiological Inspection Equipment

The homogeneity of weld seams examined by radiological methods shall be determined by means of X-rays directed through the weld material in order to create a suitable image on radiographic film. The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table 2 of ASTM E 94, with minimum density greater than 1.8 measured in connection with radiographic image of the welding and shall be suitable to allow a sensitivity of at least 1 .8 percent of nominal wall thickness. 9.8.4.2

Radiological Sensitivity Reference Standard

The reference standard shall be ISO wire-type image quality indicator described in 9.8.4.4. 9.8.4.8

Defects Observed During Radiological Inspection

Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe material shall be removed by cutting off the section of pipe containing these defects. The remaining defects-free section of the pipe will be acceptable provided its length is within the specified minimum length, the weld at the new pipe end contains no defects other than those permitted. 9.8.5

Ultrasonic and Electromagnetic Inspection

9.8.5.1

Equipment

All automatic ultrasonic equipment shall have an alarm device, which continuously GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 16 of 36

Copyright GAIL – All rights reserved

monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre. 9.8.5.2

Ultrasonic and Electromagnetic Inspection Reference Standards

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 Figure 9.8.5.2 of this specification and as given below: -

Two longitudinal inside notches of type N 5 at both edges of weld seam.

-

Two longitudinal outside notches of type N5 at both edges of weld seam.

Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. Two transverse notches of type N5 across the weld seam, one outside and one inside. A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm The reference standard for plate/skelp UT shall contain continuous machined notch of 8 mm width x½ t depth, where ‘t’ is the specified wall thickness. The reference standard for plate/skelp edge UT and pipe ends shall have ¼ inch dia FBH X1/2 t depth, where 't' is the specified wall thickness. The calibration shall be performed at following intervals: a.

At the beginning of each operating shift (12 hours maximum).

b.

At least once during each operating shift (12 hours maximum).

c.

Every time the running of the system gives rise to doubts on its efficiency.

If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or plate/skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4 Acceptance limits 9.8.5.4.1Plate/Skelp Edges GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 17 of 36

Copyright GAIL – All rights reserved

(New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2.

Maximum length of imperfection in any direction shall not exceed 30 mm.

3.

Maximum area of individual imperfection shall not exceed 500 mm2.

4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.5.4.2

Remaining Plate/Skelp

(New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8 mm. (The length is the dimension at right angles to the scan track-and the width is the dimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per I m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7

Residual Magnetism Measurement Requirements

The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be recorded. 9.9

DISPOSITION OF PIPE CONTAINING DEFECTS

a. The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with 9.9 (c) or (d). b.

Repair welding on parent metal is not permitted.

In addition to all NDT requirements random radiography of0.1%the total length shall be done. The area to be radiographed shall be at the sole discretion of the Third Party Inspection GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 18 of 36

Copyright GAIL – All rights reserved

Agency. 9.10

TEST METHODS

9.10.3

Guided-bend Test

One face and one root guided bend weld test shall be made on samples cut from pipe. The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. The dimension 'A' in guided bend test shall not exceed 4.0 times the thickness of the specimen. 9.10.4

Charpy Test

Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification. 9.12

RETESTS

9.12.1

Recheck Analysis

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. 9.12.6

Charpy Retests

In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then the entire pipe in that lot, with the exception of the original selected length, shall be considered to meet the requirement. 9.13

REPROCESSING

This para stands cancelled. 10

Marking

10.1

GENERAL

Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be in English language and International System (SI) of units. Marking shall comply with Appendix I of API Spec 5L, and as modified in this specification. 11

Coating and Protection

11.1

COATINGS

Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coating. 12

Documents

12.1

CERTIFICATION

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 19 of 36

Copyright GAIL – All rights reserved

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. 12.2

RETENTION OF RECORDS

In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/plate/skelp as well as pipe ends. 12.3

PRODUCTION REPORT

(New) 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: -

All test certificates as per SR 15.1.

-

Records of qualification of welders and procedures for repair welding.

-

Certified reports of dimensional, workmanship and defects inspection.

-

Data on test failures, rejected heats/lots, etc.

-

All other reports and results required as per this specification.

The certificates shall be valid only when signed by the Purchaser's Representative. Only those pipes, which have been certified by the Purchaser's Representative shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, 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 5L and other test reports/results required as per this specification. 12.4

LINE PIPE TRACEABLITY DATA

(New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer and shall include, but not limited to, the following: GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 20 of 36

Copyright GAIL – All rights reserved

- All marking information - Data of skelp and pipe manufacture - All mechanical properties from test results - All dimensional records - All workmanship and defects inspection records - Final inspection and release date - Description and disposition of repairs - Load-out /dispatch date - Destination - Consignment details. 14

Inspection of Field Test & Warranty

(New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not be postponed because of absence of the Manufacturer's Representative.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 21 of 36

Copyright GAIL – All rights reserved

APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.I. 2

WELD SEAM OF WELDED PIPE

B. 1.2.1 Repaired welds shall be inspected both by X-ray and UT. B.3

Procedure for Repair of Submerged-Arc and Gas Metal-Are Welds

B.3.1 The defective part of the weld shall be clearly marked on the pipe so that the defect can be easily located and repaired. B.3.2

Following requirements shall also be complied with for repair welding;

a.

No repair of weld seam is permissible after cold expansion.

b.

No repair of weld seam is permissible at pipe ends up to a length of 300 mm.

c. Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Maximum two repairs per pipe are allowed. d.

Repair welding shall be executed only after specific approval by Purchaser

Representative for each repair. e.

No repair of a repaired weld is permitted.

f.

The repair weld shall be performed with a minimum of two passes.

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 22 of 36

Copyright GAIL – All rights reserved

AFPENDIX- C REPAIR WELDING PROCEDURE (NORMATIVE) C.2

Repair Welding Procedure Qualification

C.2.2

Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test The radius of male member of the jig used for guided bend teats 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 the new HAZ of the repaired area.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 23 of 36

Copyright GAIL – All rights reserved

APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5

Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 ½ or Larger

SR 5.1 The Manufacturer shall perform Charpy V-notoh test for determining Shear Area. SR 5.3 The specimen shall be full sized or largest obtainable, sub size in case pipeline diameter and thickness does not permit full size specimen. SR 5.4

Flattened specimen shall not be used.

SR 5.5 This para stands deleted. SR 5A

Shear Area

SR 5A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness, SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32°F (0°C). The average shear value of the fracture appearance of the three specimen shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%. Note: 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 Mot'. Lot shall be as per SR5A.1 as above. SR6

Drop Weight Tear Testing (DWTT) on Welded Pipe

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 mare for the specified test temperature. Note: Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by Hot'. Lot shall be as per SR6.2 as above. SR19 Additional Fracture Toughness Requirements (Transverse Charpy V-Notch) for PSL 2 Pipe SR 19.1 Except as allowed by SR 19.2 of API Spec 5L,, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 24 of 36

Copyright GAIL – All rights reserved

as modified in this specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified in the Purchase Order. The required minimum all heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API Spec. SL, the minimum average absorbed energy value shall be 1.5 times that applicable for transverse specimen. The required minimum average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 25 of 36

Copyright GAIL – All rights reserved

APPENDIX-H PURCHASER INSPECTION (NORMATIVE) H.4

Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, tins shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 26 of 36

Copyright GAIL – All rights reserved

APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.1

General

1.1.1 Marking shall also include API monogram, Purchase Order number, item number, pipe number, wall thickness (mm), heat number and weight. 1.2

Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencil marking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. 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.

1.3

Sequence of Marking

1.3.4 Specified Dimensions: Actual pipe weight in kg shall also be marked. 1.3.5 Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends. 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 tow 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 27 of 36

Copyright GAIL – All rights reserved

ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION 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. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 28 of 36

Copyright GAIL – All rights reserved

In addition to the WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. - Method of weld defect removal. - Detailed methodology of cold expansion. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 29 of 36

Copyright GAIL – All rights reserved

ANNEXURK -II(NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. These first day's production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In addition ,change of width of coil shall also call for first day production tests. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated against the corresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from the radiograph, a cross section of the weld, at the location of the abovementioned ultrasonic indication shall be made in such a way that the nature of the imperfection can definitely be established. c. Radiographic Examination The weld seam of all pipes shall be examined radiographically for the entire length. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 30 of 36

Copyright GAIL – All rights reserved

The following tests shall be conducted: i. Four (4) weld guided bend test specimen transverse to the longitudinal weld shall be removed. Of the four specimens, two specimens shall be used for the face bend test and two for the root bend test. ii. Tensile tests shall be conducted on: -

Two (2) transverse base material specimens.

-

Two (2) transverse weld material specimen of the longitudinal weld.

-

Two (2) cylindrical all-weld specimen of the longitudinal weld.

iii. Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be taken for metallographic examination. Two of these specimens shall be tested for hardness at room temperature after etching. iv. Fracture toughness testing specimen shall be extracted as follows: -

Four sets of three transverse specimen each from base metal

-

One set of 3 transverse specimen with weld in middle

-

One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 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 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. 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 31 of 36

Copyright GAIL – All rights reserved

ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 32 of 36

Copyright GAIL – All rights reserved

FIGURE: 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 33 of 36

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 34 of 36

Copyright GAIL – All rights reserved

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

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 35 of 36

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR LONGITUDINAL SEAM SUBMERGED ARC WELDING (LSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-001

REV-0 Page 36 of 36

Copyright GAIL – All rights reserved

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

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 1 of 43

Copyright GAIL – All rights reserved

Abbreviations: ASTM

American Society for Testing and Materials

API

American Petroleum Institute

ID

Inside Diameter

HSAW

Helical Seam Submerged Arc Welded

HAZ

Heat Affected Zone

NDT

Non Destructive Testing

NPS

Nominal Pipe Size

OD

Outside Diameter, Specified

WT

Wall Thickness, Specified

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 2 of 43

Copyright GAIL – All rights reserved

CONTENTS 1

SCOPE

2

REFERENCES

5

PROCESS OF MANUFACTURE AND MATERIAL

6

MATERIAL REQUIREMENTS

7

DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

9

INSPECTION AND TESTING

10

MARKING

11

COATING AND PROTECTION

12

DOCUMENTS

14

(New) INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-B

REPAIR OF DEFECTS BY WELDING (NORMATIVE)

APPENDIX-C

REPAIR WELDING PROCEDUR (NORMATIVE)

APPENDIX-F

SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR 5

FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4½ OR LARGER

SR 6

DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER.

SR 7

ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR

PSL 2 PIPE APPENDIX-H

PURCHASER INSPECTION (NORMATIVE)

APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 3 of 43

Copyright GAIL – All rights reserved

ANNEXURE-I

MANUFACTURING PROCEDURE SPECIFICATION

ANNEXURE-II

FIRST DAY PRODUCTION TESTS (New)

FIGURE 6.2.6.1

METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

FIGURE 6.2.6.2

LOCATIONS FOR HARDNESS MEASUREMENT

FIGURE 7.8.3

PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD

FIGURE9.8.5.2 SEAM

REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 4 of 43

Copyright GAIL – All rights reserved

1.

SCOPE

1.1

PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of helical (spiral) seam submerged arc welded steel line pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and makes restrictive amendments to API Spec. 5L. 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.

1.2

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL

2. 1.3

GRADE This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

DIMENSIONS This specification shall be applied to line pipe of size 18 through 48 (both sizes included)

2.0

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 E 92

:

Test Method for Vickers Hardness of Metallic Materials.

ASTM R 112

:

Standard Test Methods for Determining Average Grain Size.

BS 5996

:

Specification

GAIL (INDIA) LTD NEW DELHI

for

the

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

Acceptance

Level

DOCUMENT No. S-04-02-002

for

Internal

REV-0 Page 5 of 43

Copyright GAIL – All rights reserved

Imperfection in Steel Plate, Strip and Wide Flats, based on Ultrasonic Testing. ASME IX

:

ASME B31.8

:

Gas Transmission & Distribution piping system.

OISD – 141

:

Oil Industries safety distribution piping system

:

Recommended practice for railroad transmission of line pip

API RP 5 L1 5

Boiler & Pressure Vessel code: Welding & brazing quality.

Process of Manufacture and Material

Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process

: Submerged Arc Welding as per para 5.1.2.2.1

Type of Pipe

: Helical Seam Submerged Arc Welded Pipe as per para 5. 1.3.11

Type of Seam Weld

: Submerged Arc Weld (Helical Seam) as per para 5.1.4.3

A manufacturing procedure specification (MPS) as described in Annexure-I of this specification shall be prepared and submitted to purchaser for approval prior to start of production. 5.1.2.2.1

Submerged Arc Welding Process The submerged arc welding equipment shall have an automatic weld tracking system capable of ensuring accurate positioning of welding head and the welding edges of the skelp.

5.2

COLD EXPANSION Pipes furnished to this specification shall be non-expanded.

5.3

MATERIAL

5.3.3

(New) GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 6 of 43

Copyright GAIL – All rights reserved

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. 5.4

HEAT TREATMENT The pipes shall be produced from skelp which shall be quenched and tempered or controlled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer.

5.5

SKELP END WELDS IN HELICAL SEAM PIPE Junctions of skelp end weld and helical seam welds in finished pipe are not permitted.

6

Material Requirements

6.1

CHEMICAL PROPERTIES

6.1.1

Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element

Product Analysis (percent by weight)

C

0.16

max

Mn

1.50

max. (For Grade B to X52)

1.60 Si

max (For Grade X56 to X70)

0.15

min

0.45

max

S

0.015

max

P

0.02

max

0.07

max

Al GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 7 of 43

Copyright GAIL – All rights reserved

Nb

0.05

max.

V

0.08

max.

Ti

0.04

max. (For Grade B

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

to X60)

max

Note: g (New) i. V+Nb +Ti shall not exceed 0.15% ii. Cu+Ni shall not exceed 0.40% iii. Al/N shall be min. 2 Note:

h (New)

If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 6.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analyzed and reported, even if those are not purposely added but are present as residuals only. 6.1.3

Carbon Equivalent (PSL 2 Only) GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 8 of 43

Copyright GAIL – All rights reserved

6.1.3.1 Calculation of Carbon Equivalent Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 6.1.3.2

Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits:

6.2 6.2.1

CE (Pcm)

≤

0.20

CE (IIW)

≤

0.40

MECHANICAL PROPERTIES Tensile Properties The finished pipe shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5 L Grade Up to and including X46 X52 to X65 X70 and above

Permissible in excess of SMYS. psi (MPa) 19,000 (131) 22,000(152) 20,000(138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal of finished pipe shall not exceed 0.90, when tested using cylindrical all weld specimen. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the formula given in foot note (a) of Table-3B and shall comply with the minimum values of API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API Spec 5L Appendix D stands modified accordingly. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 9 of 43

Copyright GAIL – All rights reserved

6.2.5

Fracture Toughness Tests

6.2.5.2

Charpy Impact Tests for PSL 2

f. (New) For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. 6.2.5.3

Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area, in accordance with Supplementary Requirement SR 5A of API' Spec 5L and as modified in this specification shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order, Drop Weight Tear Test in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size, grade and wall thickness.

6.2.6

Metallographic Examination

6.2.6.1(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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 10 of 43

Copyright GAIL – All rights reserved

value at any point shall not exceed 248 HV10. Modalities of retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7

Residual Stress Test (New) Helical pipes shall meet the testing and minimum acceptance criteria set forth in this paragraph. The residual stress test shall be carried out on the pipe after hydrostatic test.

6.2.7.1

Testing Frequency (New) One test shall be carried out at the beginning of each shift. Minimum of one test shall be carried out for pipes of each grade, size and specified wall thickness. In addition, whenever the production line settings are changed, the first produced pipe shall be tested for residual stress.

6.2.7.2

Test Specimen (New) The 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.

6.2.7.3

Testing (New) The specimen ring shall be severed by flame cutting or sawing parallel to the longitudinal axis of the pipe. The cut shall be 180 degree from the spiral weld. (Specimen ring shall be allowed to cool down to ambient temperature prior to cutting)

6.2.7.4

Computation of Residual Stress (New) The increase in circumference, if any, after severing shall be measured using fiducial marks of known separation on the specimen prior to severing. The residual stress then shall be calculated using following formula. S = {(E*t*C)/(12.556 *R2)}-{(F*R2)/t} Where: S

-

Residual Stress, kPa (psi)

C

-

Increase in circumference, mm (in)

t

-

Specified wall thickness, mm (in)

E

-

Young's Modulus of Elasticity, 2 x 108kPa, (29 x 106psi)

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 11 of 43

Copyright GAIL – All rights reserved

6.2.7.5

R

-

Pipe Radius, mm (0.5 * Specified outside diameter), mm (in)

F

-

0.1154 in SI units, (0.425 in conventional units)

Acceptance Criteria (New) The computed residual stress shall not exceed 10% of the Specified Minimum Yield Stress (SMYS) of the pipe.

6.2.7.6

Retests (New) If any specimen fails to meet the requirements of paragraph 6.2.7.5 above, the pipe may be retested once. The retest specimen shall be obtained from the same end of the pipe from where the failed specimen was obtained. If the results obtained from the retest specimen are acceptable, normal test schedule shall be resumed. If the results obtained from retest specimen are not acceptable, the pipe shall be rejected and testing shall resume on the next pipe in the production line. If this test also fails all pipes back to the last acceptable test shall be individually tested and those 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

Dimensions, Weights, Lengths, Defects and End Finishes

7.2

DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6C, Appendix E. API Spec 5L, Table 7 stands modified accordingly. Size

Tolerance

18

± 3mm

> 20 and 36 GAIL (INDIA) LTD NEW DELHI

+ 3 mm, - 0.25% of specified OD ± 3mm. SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 12 of 43

Copyright GAIL – All rights reserved

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

:

12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13 shall also be applicable.

9.3.1.4

Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen.

9.3.1.5

Weld Tensile Tests Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first day production test as specified in Annexure-II of this specification to determine the yield strength, ultimate tensile strength and elongation.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 17 of 43

Copyright GAIL – All rights reserved

The cylindrical all weld specimen shall have gauge length, L = 5d, where; L

=

D =

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

The results of the 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,” 9.3.5

Fracture Toughness Tests

9.3.5.1

Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with heat affected zone (HAZ) in the middle shall also be taken.

9.3.5.2

Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimens each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness.

9.4

HYDROSTATIC TESTS

9.4.1

Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for each pipe of all sizes and grades.

9.4.2

Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and records shall be maintained.

9.4.3

Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5L para 9.4.3 (Note 2). GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 18 of 43

Copyright GAIL – All rights reserved

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. 9.5

DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request.

9.7

VISUAL INSPECTION All pipes shall be visually examined both externally and internally (to the extent feasible) and shall he free of defects in the finished condition.

9.8

NON DESTRUCTIVE INSPECTION The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice: plant access, compliance and rejection mentioned in Appendix H of API Spec 5L. The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in-strict accordance with this specification.

9.8.1

Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TCMA or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 19 of 43

Copyright GAIL – All rights reserved

Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below: (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 Evaluation of indications

:

Level I, II, III inspector

Supervision

:

Level II or Level III inspector (in case evaluation is by Level I

inspector) 9.8.3

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of weld seam shall be performed after 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. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Ends Inspection The full circumference of both ends of each pipe after bevelling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. In addition, full circumference of both ends of each pipe shall be 100 % ultrasonically tested over a circumferential width of at least 50 mm with angular probes to detect cracks, in case of non-availability of angular probes at the mill, the full circumference of both ends of each pipe shall be inspected with magnetic particle GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 20 of 43

Copyright GAIL – All rights reserved

technique over a circumferential width of at least 50 mm to detect surface cracks. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table-24) using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be re-examined by radiography, if during production, repeated ultrasonic indications occur requiring re-inspection by radiography and it appears from radiographs that the nature of defects causing the ultrasonic indications cannot be definitely established, the Manufacturer shall prove by other inspection methods (e.g. by making some cross-sections in accordance with para 6.2.6 of this specification at locations where such indications occur near the end of the pipe) to the satisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 9.8.3.1

Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged-arc weld seam shall be radio graphically examined for a minimum distance of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be recorded.

9.8.4

Radiological Inspection-Weld Seams

9.8.4.1

Radiological Inspection Equipment The homogeneity of weld seams examined by radiological methods shall be determined by means of X-rays directed through the weld material in order to create a suitable image on radiographic film. The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table-2 of ASTM E 94; with minimum density greater than 1.8 measured in connection with radiographic image of the welding and shall be suitable to allow a sensitivity of at least 1.8 percent of nominal wall thickness.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 21 of 43

Copyright GAIL – All rights reserved

9.8.4.2

Radiological Sensitivity Reference Standard The reference standard shall be ISO wire-type image quality indicator described in 9.8.4.4.

9.8.4.8

Defects Observed During Radiological Inspection Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe material shall be removed by cutting off the section of pipe containing these defects. The remaining defects-free section of the pipe will be acceptable provided its length is within the specified minimum length, the weld at the new pipe end contains no defects other than those permitted.

9.8.5

Ultrasonic and Electromagnetic inspection

9.8.5.1

Equipment All automatic ultrasonic equipment shall have an alarm device, which continuously monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre.

9.8.5.2

Ultrasonic and Electromagnetic Inspection Reference Standards The reference standard (calibration pipe) shall have the same specified diameter and wall thickness as specified for the production pipe being inspected and shall be of sufficient length to permit calibration of ultrasonic inspection equipment at the speed to be used in normal production. The reference standard (calibration pipe) shall also be of the same material, type and have the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches/holes as per as per Figure 9.8.5.2 of this specification and as given below; - Two longitudinal inside notches of type N 5 at both edges of weld seam. - Two longitudinal outside notches of type N5 at both edges of weld seam. - Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. - Two transverse notches of type N5 across the weld seam, one outside and one inside.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 22 of 43

Copyright GAIL – All rights reserved

- A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm. The reference standard for skelp UT shall contain continuous machined notch of 8 mm width x ½ t depth, where “t”is the specified wall thickness. The reference standard for skelp edge UT and pipe ends shall have ¼” inch dia FBH x ½ t depth, where “t” is the specified wall thickness. The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency. If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4

Acceptance limits

9.8.5.4.1 Skelp Edges (New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec L, para 9.9 (c) or (d). 9.8.5.4.2 Remaining Skelp (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 23 of 43

Copyright GAIL – All rights reserved

1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width : 8 mm. (The length is the dimension at right angles to the scan track and the width is the dimension parallel to the scan track) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the skelp surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). Residual Magnetism Measurement Requirements

9.8.7

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. 9.9

DISPOSITION OF PIPE CONTAINING DEFECTS 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.

9.10

TEST METHODS

9.10.3

Guided-bend Test One face and one root guided bend weld test shall be made on samples cut from pipe. The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. The dimension ‘A’ in guided bend test shall not exceed 4.0 times the thickness of the specimen.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 24 of 43

Copyright GAIL – All rights reserved

9.10.4 Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification. 9.12

RETESTS

9.12.1

Recheck Analysis 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.

9.12.7

Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then all pipes in that lot, with the exception of the original selected length, shall be considered to meet the requirement.

9.13

REPROCESSING This para stands cancelled.

10

Marking

10.1

GENERAL Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be in English language and international system (SI) of units. Marking shall comply with Appendix-I of API Spec 5L and as modified in this specification.

11 11.1

COATING AND PROTECTION 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 12.1

Documents CERTIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 25 of 43

Copyright GAIL – All rights reserved

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. 12.2

RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends.

12.3

PRODUCTION REPORT (New) 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: - All test certificates as per SR 15.1. - Records of qualification of welders and procedures for repair welding. - Certified reports of dimensional, workmanship and defects inspection. - Data on test failures, rejected heats/lots, etc. - Alt other reports and results required as per this specification. The certificates shall be valid only when signed by the Purchaser's Representative. Only those pipes, which have been certified by the Purchaser's Representative, shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, 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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 26 of 43

Copyright GAIL – All rights reserved

5L and other test reports/results required as per this specification. 12.4

LINE PIPE TRACEABILITY DATA

(New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer and shall include, but not limited to, the following: - All marking information - Data of skelp and pipe manufacture - All mechanical properties from test results - All dimensional records - All workmanship and defects inspection records - Final inspection and release date - Description and disposition of repairs - Load-out /dispatch date - Destination - Consignment details. 14

Inspection of Field Tests & Warranty (New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not be postponed because of absence of the Manufacturer's Representative.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 27 of 43

Copyright GAIL – All rights reserved

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

Weld Seam of Welded Pipe

B.I.2.1

Repaired welds shall be inspected both by X-ray and UT.

B.3

Procedure for Repair of Submerged-Arc and Gas Metal-Arc Welds

B 3.1

The defective part of the weld shall be clearly marked on the pipe so that the defect can be easily located and repaired.

B.3.2

Following requirements shall also be complied with for repair welding: a.

No repair of weld seam is permissible alter hydrostatic testing.

b.

No repair of weld seam is permissible at pipe ends up to a length of 300 mm.

c.

Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Maximum two repair per pipe are allowed.

d.

Repair welding shall be executed only Purchaser Representative for each repair.

e.

No repair of a repaired weld is permitted.

f.

The repair weld shall be performed with a minimum of two passes.

after specific approval by

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 28 of 43

Copyright GAIL – All rights reserved

APPENDIX-C REPAIR WELDING PROCEDURE (NORMATIVE) C.2

Repair Welding Procedure Qualification

C.2.2

Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test The radius of male member of the jig used for guided bend tests shall be RA =2.25 t, where “t” is specified wall thickness of pipe. C.2.2.5 (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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 29 of 43

Copyright GAIL – All rights reserved

PPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Larger

Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 1/2 or

SR 5.1

The Manufacturer shall perform Charpy V-notch test for determining Shear Area.

SR 5.3

The specimen shall be full sized or largest obtainable sub size in case pipeline diameter and thickness does not permit full size specimen

SR 5.4

Flattened specimen shall not be used.

SR 5.5

This para stands deleted.

SR 5A

Shear Area

SR 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.

SR 6

Drop Weight Tear Testing (DWTT) on Welded Pipe

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 30 of 43

Copyright GAIL – All rights reserved

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.

SR19

Additional Fracture Toughness Requirements (Transverse Charpy VNotch) for PSL 2 Pipe

SR 19.1

Except as allowed by SR 19.2 of API Spec 5L, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and as modified in this specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified in the Purchase Order. The required minimum all-heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19 (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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 31 of 43

Copyright GAIL – All rights reserved

APPENDIX- H PURCHASER INSPECTION (NORMATIVE) H.4

Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 32 of 43

Copyright GAIL – All rights reserved

APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.0

General

1.1

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

1.2

Location of Markings Paint used for stencil marking shall withstand a temperature up to 250°C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator.

1.3

Sequence of Marking

1.3.4

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

1.3.5

Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of ISO mm from the pipe ends.

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 33 of 43

Copyright GAIL – All rights reserved

ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION 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. - 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 skelp 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. In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 34 of 43

Copyright GAIL – All rights reserved

pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. - Method of weld defect removal. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 35 of 43

Copyright GAIL – All rights reserved

ANNEXURE -II (NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. These first day’s production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In addition, change of width of coil shall also call for first day production test. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes- in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated against the corresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from the radiograph, a cross section of the weld, at the location of the above-mentioned ultrasonic indication shall be made in such a way that the nature of the imperfection can definitely be established. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 36 of 43

Copyright GAIL – All rights reserved

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. The following tests shall be conducted: i.Four (4) weld guided bend test specimen transverse to the helical weld shall be removed. Of the four specimen, two specimen shall be used for the tact- bend test and two for the root bend test. ii.Tensile tests shall be conducted on: - Two (2) transverse base material specimen. - Two (2) transverse weld material specimen of the helical weld. - Two (2) cylindrical all-weld specimen of the helical weld. iii.Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be taken for metallographic examination. Two of these shall be tested for hardness at room temperature after etching. iv.Fracture toughness testing specimen shall be extracted as follows: -

Four sets of three transverse specimen each from base metal

-

One set of 3 transverse specimen with weld in middle

-

One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 37 of 43

Copyright GAIL – All rights reserved

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 38 of 43

Copyright GAIL – All rights reserved

ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 39 of 43

Copyright GAIL – All rights reserved

FIGURE : 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 40 of 43

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 41 of 43

Copyright GAIL – All rights reserved

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

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 42 of 43

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-002

REV-0 Page 43 of 43

Copyright GAIL – All rights reserved

SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

GAIL (INDIA) LTD NEW DELHI

STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

REV-0 Page 1 of 6

Copyright GAIL – All rights reserved

CONTENTS S.No.

Description

Page No.

1

INTENT OF SPECIFICATION

2

2

SCOPE OF WORK

2

3

COVERAGE

2

4

REFERENCES

2

5

MANUFACTURING PROCESS

2

6

INSPECTION & TESTING

3

7

MARKING & DESPATCH

3

GAIL (INDIA) LTD NEW DELHI

STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

REV-0 Page 2 of 6

Copyright GAIL – All rights reserved

1.0

INTENT OF SPECIFICATION

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. 5L2000 shall be valid.

2.0

SCOPE OF WORK

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 GAIL (INDIA) LTD NEW DELHI

STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

REV-0 Page 3 of 6

Copyright GAIL – All rights reserved

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 5.0

MANUFACIURING PROCESS

5.1

Steel made by acid Bessemer process shall not be acceptable.

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.

6.0

INSPECTION & TESTING

6.1

All pipes shall be hydrostatically tested. The test mill pressure shall be as follows: GROUP 1 (SEAMLESS,ERW & SPIRAL WELDED) A

S No.

CARBON STEEL

(i) (ii) (iii) (iv) (v)

MATERIAL STD ASTM A106 GR.B API 5L GR.B,SEAMLESS API 5L,E.R.W API 5L,SPIRAL ASTM A333 GR.3 & 6,SEAMLESS

(vi)

ASTM

B

S No. (i) (ii)

A333 GR.3

&

6,E.R.W

:

TEST PRESSURE

: : : : :

ASTM A 530 API 5L API 5L API 5L ASTM A530

:

ASTM A530

:

TEST PRESSURE

:

ASTM A530

:

ASTM A530

SEAMLESS ALLOY STEEL MATERIAL STD ASTM GR.P1,P12,P11,P22,P5,Pg ASTM A268 TP 405,TP410

GAIL (INDIA) LTD NEW DELHI

A335

STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

REV-0 Page 4 of 6

Copyright GAIL – All rights reserved

C

S No.

SEAMLESS STAINLESS STEEL

(i)

MATERIAL STD ASTM A312 GR. TP304 ,304L ,304H, 316, 316L, 316H, 321, 347

D

SEAMLESS NICKEL ALLOY

S No. (i) (ii) (iii) (iv)

MATERIAL STD ASTM B161 UNS ASTM B165 UNS ASTM A167 UNS ASTM A407 UNS

NO2200 NO4400 NO6600 NO8800

:

TEST PRESSURE

:

ASTM A530

:

TEST PRESSURE

: : : :

ASTM B161 ASTM B165 ASTM B167 ASTM B407

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.

7.0

MARKING & DESPATCH

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.

GAIL (INDIA) LTD NEW DELHI

STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

REV-0 Page 5 of 6

Copyright GAIL – All rights reserved

7.6

Both ends of pipes (Bevelled Ends) shall be protected with wood, metal or plastic cover.

7.7

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

GAIL (INDIA) LTD NEW DELHI

STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

REV-0 Page 6 of 6

Copyright GAIL – All rights reserved

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 1 of 34

Copyright GAIL – All rights reserved

CONTENTS 1

SCOPE

2

REFERENCES

5

PROCESS OF MANUFACTURE AND MATERIAL

6

MATERIAL REQUIREMENTS

7

DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

9

INSPECTION AND TESTING

10

MARKING

11

COATING AND PROTECTION

12

DOCUMENTS

14

(New) INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-F

SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR 5

FRACTURE TOUCHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4½ OR LARGER

SR 6

DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER PIPE AND LASER

SR 17

NON DESTRUCTIVE INSPECTION OF WELDS IN ELECTRIC WELDED PIPE AND LASER WELDED PIPE

SR 19

ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE

APPENDIX-H

PURCHASER INSPECTION (NORMATIVE)

APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEE (NORMATIVE)

ANNEXURE-I

MANUFACTURING PROCIDURE (New)

ANNEXURE-II

FIRST DAY PRODUCTION TESTS (New)

FIGURE 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT FIGURE 6.2.7

REVERSE BEND TEST

FIGURE 9.8.5.2 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 2 of 34

Copyright GAIL – All rights reserved

Abbreviations: ASTM

American Society for Testing and Materials

API

American Petroleum Institute

ID

Inside Diameter

EW

Electric Welded

HAZ

Heat Affected Zone

NDT

Non Destructive Testing

NPS

Nominal Pipe Size

OD

Outside Diameter, Specified

WT

Wall Thickness, Specified

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 3 of 34

Copyright GAIL – All rights reserved

1. Scope 1.1

PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinal seam electric welded steel tine 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 as that of API Spec SL 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.

1.2

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL 2.

1.3

GRADES This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

DIMENSIONS This specification shall be applied to line pipe of size 4 1/2 through 20 (both sizes included),

2.

References

2.1

The latest editions (edition enforce at the time of issue of enquiry) of following additional references are included in this specification: ASTM ASTM E 92

: Test Method for Vickers Hardness of Metallic Materials.

ASTM E 112 : Standard Test Methods for Determining Average Grain Size. BS BS 5996

GAIL (INDIA) LTD NEW DELHI

: Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats, based on Ultrasonic Testing. SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 4 of 34

Copyright GAIL – All rights reserved

OISD –141

: Oil industry safety Directorate Standard for Design and Construction Requirements for Cross country Hydrocarbon Pipeline : Boiler & Pressure Vessel code: Welding & brazing quality. : Gas Transmission & Distribution piping system. : Recommended practice for railroad transmission of line pipe

ASME IX ASME B31.8 API RP 5 L 5

Process of Manufacture and Material

5.1

PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process

:

Electric Welding as per para 5.1.2.1.2.

Type of Pipe

:

Electric Welded Pipe as per para 5.1.3.3 & 5.1.3.3.2.

Type of Seam Weld

:

Electric Weld as per para 5.1 .4.1.

5.1.3.3.2 PSL 2 ELECTRIC WELDED PIPE Electric welding shall be performed with a minimum welder frequency of 200 kHz. The welding system shall have an integrated control in which following data as a minimum shall be monitored: -

Time

-

Welding speed

-

Current and Voltage

-

Heat treatment temperature

The weld seam and the entire Heat Affected Zone (HAZ) shall be heat treated so as to stimulate a normalizing heat treatment in order to control the structure so that no untempered martensite remain in the weld seam and the HAZ, and the mechanical properties of heat treated zone approximate that of the parent metal. 5.2

COLD EXPANSION Pipes furnished to this specification shall be non-expanded.

5.3

MATERIAL

5.3.3 (New) Line pipe furnished to this specification shall be made from steel produced in basic oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel shall be made by continuous casting only. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 5 of 34

Copyright GAIL – All rights reserved

5.4

HEAT TREATMENT The pipes shall be produced from skelp which shall be quenched and tempered or controlled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer.

6

Material Requirements

6.1

CHEMICAL PROPERTIES

6.1.1

Chemical Composition The chemical composition of each heat of steel on product analysts shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight 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)

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

Si

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 6 of 34

Copyright GAIL – All rights reserved

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 7 of 34

Copyright GAIL – All rights reserved

Note: h (New) If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 6.1.2

Elements Analyzed 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.

6.1.3 6.1.3.1

Carbon Equivalent (PSL 2 Only) Calculation of Carbon Equivalent Boron content shall be considered in CE (Pcm) formula even if it is less than 0.0005%.

6.1.3.2

Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits: CE (Pcm) ≤

0.20 %

CE (IIW) ≤

0.40 %

6.2

MECHANICAL PROPERTIES

6.2.1

Tensile Properties The finished pipe (after all heat treatment and expansion or sizing operations) shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5L Grade

Permissible in excess of SMYS. psi (MPa)

Up to and including X46

19,000 (131)

X52 to X56

22,000(152)

X70

20,000(138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90. 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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 8 of 34

Copyright GAIL – All rights reserved

formula given in the foot note (a) of Table-3B and shall comply with the minimum values of API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API Spec 5L Appendix D stands modified accordingly. 6.2.2

Flattening Test Acceptance Criteria Dye penetrate testing may be used to positively confirm the presence of crack, break or opening.

6.2.5

Fracture Toughness Tests

6.2.5.2

Charpy Impact Tests for PSL 2

f. (New)

For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone.

6.2.5.3

Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area in accordance with Supplementary Requirement SR 5 A of API Spec 5L and as modified herein 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 for pipe size 16” and larger, Drop Weight Tear Test (DWTT) in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all grades and wall thickness.

6.2.6

Metallographic Examination

6.2.6.1 (New) A test specimen for metallographic & hardness examination shall be taken transverse to the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) which ever 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 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 heat treatment of weld zone is adequate and there is no untempered martensite left. 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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 9 of 34

Copyright GAIL – All rights reserved

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. Indentation in the Heat Affected Zone (HAZ) shall start as close to the fusion line as possible. The resulting Vickers hardness value at any point shall not exceed 248 HV10. The maximum difference in hardness between (the base metal and any reading taken on the weld or heat affected zone shall be less than 80 HV10. Modalities of retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7

Reverse Bend Test

6.2.7.1 (New) Reverse bend test shall be executed with the some number of tests and retests specified for flattening test in para 9.3.2 of API Spec 5L. Ring Specimen of width 100 mm to 115 mm shall be taken from the pipe and tested in accordance with the procedure given below and Fig. 6.2.7 of this specification. 6.2.7.2

Selection of Mandrel The reverse bend test shall be carried out with a mandrel, whose radius (R), or width (A) shall be calculated for any combination of diameter, wall thickness and grade with the following formula:

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

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 10 of 34

Copyright GAIL – All rights reserved

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. 7

Dimensions, Weights, Lengths, Defects and End Finishes

7.1

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-6B (for size 4 ½) and E-6 C (for size ≥ 6 5/8 ) Appendix E. API Spec 5L Table 7 stands modified accordingly. Pipe Size

Tolerance

>4 1/2 and≤18

± 0.75 % of Specified OD or ± 3 mm whichever is smaller

20

+3 mm, - 0.25% of Specified OD

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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 11 of 34

Copyright GAIL – All rights reserved

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). 7.3

WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wall thickness shall be (+)15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.5

LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0m. 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. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 12 of 34

Copyright GAIL – All rights reserved

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 Jointers on pipes are not permitted.

7.8

WORKMANSHIP AND DEFECTS

7.8.1

Dents Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable.

7.8.2

Offset of Plate Edges 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).

7.8.5

Height of Flash of Electric Welded Pipe Each pipe shall be checked for conformance of height of flash. Height of flash shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.7

Trim of Inside Flash of Electric Welded Pipe and Trim of Inside Weld Reinforcement of Laser Welded Pipe Each pipe shall be checked for conformance of depth of trim. Depth of trim shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.8.8

Hard Spots 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.

7.8.9

Cracks, Sweats and Leaks Sections of the pipe containing cracks, sweats and leaks shall he cut off as per the requirement of API Spec 5L para 9.9 (c) or (d).

7.8.10

Laminations

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 13 of 34

Copyright GAIL – All rights reserved

Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of defects on the skelp/pipe body shall be as per para 9.8.5.4 of this specification. 7.8.11

Arc Burns Arc burns produced during the manufacturing of pipes are injurious defects and shall be disposed off in accordance with the requirements of API Spec 5L para 9.9 (c) or (d). As a reference method for conforming the existence of an arc burn, the area shall be buffed with wire brush or sanding disc and etched with 5 percent nital solution. However, arc burns can be considered for acceptance, in case the same is recrystallized by seam heat treatment. In such case, the Manufacturer shall demonstrate the recrystallization to Purchaser by taking a sample as per para 6.2.6.1 (New) of this specification.

7.8.14

Other Defects Any imperfection (measured from the surface) with a depth greater than 5 % of the specified thickness of the pipe shall be considered a defect and shall be repaired in accordance with API Spec 5L para 9.9 and as modified in this specification.

7.9

PIPE ENDS

7.9.1

General Pipes shall be furnished with plain ends.

7.9.3

Plain Ends 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 re-bevelling. In case root face of bevel is less than that specified, the pipe ends shall be re-bevelled and rectification by filing or grinding shall not be done.

7.9.6

Bevel Protectors (New) 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 14 of 34

Copyright GAIL – All rights reserved

9

Inspection and Testing

9.2

TESTING OF CHEMICAL COMPOSITION

9.2.1

Heat Analysis Where the steel milt is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production.

9.2.2

Product Analysis

9.2.2.1

Sampling Frequency Two pipes per inspection lot shall be analyzed. 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 arc also represented.

9.2 2.2

Sampling Method

9.2.2.22 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from skelp may be used provided the traceability of samples is guaranteed. 9.3

TESTING OF MECHANICAL PROPERTIES

9.3.1

Tensile Tests Tensile properties shall be determined from specimen removed from pipe which has been subjected to all mechanical and heat treatment operations.

9.3.1.2

Tensile Testing Frequency Tensile tests shall be made at the frequency of two pipes per inspection lot. Inspection lot shall be 100 pipes per heat, API spec Table 13 stands modified accordingly.

9.3.1.3

Longitudinal Tensile Tests Longitudinal tensile tests shall be carried out on a strip specimen.

9.3.1.4

Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen.

9.3.1.5

Weld Tensile Tests

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 15 of 34

Copyright GAIL – All rights reserved

Inside and outside flash of weld 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. 9.3.5

Fracture Toughness Tests

9.3.5. 1

Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with Heat Affected Zone (HAZ) in the middle shall also be taken. When either full size or sub-size transverse specimen as per API Spec 5L, Table 14 is not possible to obtain, transverse specimen of either Size 1/3 or 1/4 Size, whichever is maximum possible, may be obtained. When such sub-size specimens are used, the acceptance of the individual / average absorbed energy values shall be established as per API Spec 5L para 9.10.4 and as modified in this specification.

9.3.5.2

Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimen each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness.

9.4

HYDROSTATIC TESTS

9.4.1

Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for all sizes and grades of pipes.

9.4.2

Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and record shall be maintained.

9.4.3

Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5 L para 9.4.3 (Note 2).

9.5

DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 16 of 34

Copyright GAIL – All rights reserved

9.8

NON DESTRUCTIVE INSPECTION The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice, plant access, compliance and rejection mentioned in Appendix H of API Spec 5L The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in strict accordance with this specification.

9.8.1

Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below:

For UT

(i)

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).

(i)

For all other NDT methods

9.8.3

Evaluation of indications

:

Supervision

:

Level I, II, III inspector Level II or Level III inspector (in case evaluation is by Level I inspector)

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of Weld seam of pipe shall be performed after hydro testing.

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 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 17 of 34

Copyright GAIL – All rights reserved

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 plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination, the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Pipe Ends Inspection The full circumference of both ends of each pipe after beveling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. Alternatively the pipe may be tested from outside prior to bevelling, in which case a band of at least 50 mm wide shall be tested to include the eventual bevelled area. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Electric welds shall be inspected by ultrasonic methods (Refer Table 24) using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5, API Spec 5L SR 17 (Appendix F) and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. 9.8.3.1

Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment.

9.8.5

Ultrasonic and Electromagnetic Inspection

9.8.5.1

Equipment All automatic ultrasonic equipment shall have an alarm device, which continuously monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre.

9.8.5.2

Ultrasonic and Electromagnetic Inspection Reference Standards

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 18 of 34

Copyright GAIL – All rights reserved

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 as per as per Figure 9.8.5.2 of this specification and as given below: One longitudinal inside notch of type N10 at the weld line One longitudinal outside notch of type N10 at the weld line The reference standard for skelp/pipe body 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/ UT of area adjoining weld seam and pipe ends shall have 1/4 inch dia FBH x ½ t depth, where’t’ is the specified wall thickness. The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency. If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4

Acceptance limits

9.8.5.4.1 Skelp Edges/Area on either side of the Longitudinal Weld Seam (New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 19 of 34

Copyright GAIL – All rights reserved

Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.5.4.2 Skelp/Pipe Body (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8 mm.” (The length is the dimension at right angles to the scan track and the width is the dimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7 e.

9.9

Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be recorded. DISPOSITION OF PIPE CONTAINING DEFECTS The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with API Spec 5L Para 9.9 (c) or (d).

9.10

TEST METHODS

9.10.4

Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 20 of 34

Copyright GAIL – All rights reserved

9.12

RETESTS

9.12.1

Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analysed to meet the requirements of Table 2B of this specification.

9.12.6

Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then all pipes in that lot, with the exception of the original selected length, shall be considered to meet the requirement.

9.13

REPROCESSING This para stands cancelled.

10

Marking

10.1

GENERAL Marking specified in 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.

11

Coating and Protection

11.1

COATINGS Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coating.

12

Documents

12.1

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 21 of 34

Copyright GAIL – All rights reserved

12.2

RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends.

12.3

PRODUCTION REPORT (New) 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: -

All test certificates as per SR 15.1.

-

Certified reports of dimensional, workmanship and defects inspection.

-

Data on test failures, rejected heats/lots, etc.

-

All other reports and results required as per this specification.

The certificates shall be valid only when signed by the Purchaser's Representative. Only that 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 5L and other test reports/results required as per this specification. 12.4

LINE PIPE TRACEABILITY DATA (New) The manufacturer shall establish and follow procedures for maintaining heat and lot identity of all pipes as per Supplementary Requirements SR 15.2 of API Spec. 5L.

14

Inspection of Field Tests & Warranty (New)

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 22 of 34

Copyright GAIL – All rights reserved

Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not he postponed because of absence of the Manufacturer's Representative.

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 23 of 34

Copyright GAIL – All rights reserved

SR6

Drop Weight Tear Testing (DWTT) on Welded Pipe

SR6.1

When required as per para 6.2.5.3 of this specification, fracture toughness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer for pipe size 16” and larger. DWTT shall be carried out in accordance with the requirements of API Spec 5L para SR 6.2 thru SR 6.8 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 lot (refer para SR 6.2 of this specification) shall exhibit a fracture appearance shear area of 75% or more for the specified test temperature.

Note:-

Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by 'lot1. Lot shall be as per SR6.2 as above.

SR17

Nondestructive Inspection of Welds in Electric Welded Pipe and Laser Welded Pipe

SR 17.1

SUPPLEMENTARY NON DESTRUCTIVE INSPECTION The weld in electric welded pipe shall be inspected full length for surface and subsurface defects and laminations by ultrasonic methods using automatic ultrasonic equipment.

SR 17.2

EQUIPMENT AND REFERENCE STANDARDS The equipment for ultrasonic inspection shall meet the requirements of para 9.8.5.1 and 9.8.5.2 of this specification. The detailed procedure shall be approved by Purchaser's Representative.

SR 17.3 ACCEPTANCE LIMITS If during production, repeated ultrasonic indications occur requiring re-inspection by other methods and it appears that the nature of defects causing ultrasonic indications can not be definitely established, the Manufacturer shall prove by other inspection methods (such as making cross-sections as per para 6.2.6.1 of this specification) that these defects are not injurious defects as stipulated in this specification. SR 17.4 DISPOSITION Disposition of defects shall be in accordance with API Spec 5L para 9.9 (c) or (d). SR19

Additional Fracture Toughness Requirements (Transverse Charpy V-Notch) for PSL 2 Pipe

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 24 of 34

Copyright GAIL – All rights reserved

SR 19.1

Except as allowed by SR. 19.2 of API Spec 5L, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and as modified in this specification, with a test temperature of 32°F (0°C) or at a lower temperature as specified in the Purchase Order. The required minimum all heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API Spec. 5L, the minimum average absorbed energy value shall be 1.5 times that applicable for transverse specimen. The required minimum all heat 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 25 of 34

Copyright GAIL – All rights reserved

APPENDIX- H PURCHASER INSPECTION (NORMATIVE) H.4

Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 26 of 34

Copyright GAIL – All rights reserved

APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.1

General

1.1.1

Marking shall also include API monogram, Purchase Order number, item number, wall thickness (mm), pipe number, heat number and weight.

1.2

Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencil marking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. Paint used for stencil marking shall withstand a temperature up to 2505C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator.

1.3

Sequence of Marking

1.3.4

SPECIFIED DIMENSIONS Actual pipe weight in kg shall also be marked.

1.35

GRADE AND CLASS A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends.

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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 27 of 34

Copyright GAIL – All rights reserved

ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION 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. 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 skelp 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. In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 28 of 34

Copyright GAIL – All rights reserved

- Method of weld defect removal. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 29 of 34

Copyright GAIL – All rights reserved

ANNEXURE-lI (NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. The 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, 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 he 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. c. 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. The following tests shall be conducted: i.

Two (2) flattening test specimen shall be removed; one specimen shall be tested with weld at 0° and other at 90°.

ii.

Two (2) transverse base metal specimen and two transverse weld specimen for tensile test shall be tested. In case transverse base metal specimen is not applicable as per Fig 3 of API Spec 5L, longitudinal specimen may be taken.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 30 of 34

Copyright GAIL – All rights reserved

iii.

Six (6) weld cross-section specimen, three (3) from each end of the pipe joint, shall be taken for metal!-'graphic examination. Two of these specimens shall be tested for hardness at room temperature after etching.

iv.

Fracture toughness testing specimen shall be extracted as follows: -

Four sets of three transverse specimen each from base metal

-

One set of 3 transverse specimen with weld in middle

-

One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 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 orp« t0 produce full transition curve. The value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi. Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. 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.

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 31 of 34

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 32 of 34

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 33 of 34

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-004

REV-0 Page 34 of 34

Copyright GAIL – All rights reserved

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 1 of 34

Copyright GAIL – All rights reserved

CONTENTS 1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

PLANT SCALE AND INSTALLATION

4.0

MATERIALS

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

6.0

MEASUREMENT AND LOGGING

7.0

COATING PROCEDURE AND QUALIFICATION

8.0

PIPE SURFACE PREPARATION

9.0

COATING APPLICATION

10.0

INSPECTION AND TESTING

11.0

HANDLING, TRANSPORTATION AND STORAGE

12.0

REPAIR OF COATING

13.0

MARKING

14.0

QUALITY ASSURANCE

ANNEXURE-I

COMBINATIONS OF COATING MATERIALS

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 2 of 34

Copyright GAIL – All rights reserved

1.0

SCOPE This specification covers the minimum requirements for supply/arrangement of all materials, plant, equipment, plant sites, consumables, utilities and application including all labour, supervision, inspection and tests etc. for application of external anti-corrosion coating of pipes by using 3 Layer Side Extruded Polyethylene coating conforming to DIN-30670, 1991, 'Polyethylene Coating for Steel Pipes and Fittings' and the requirements of this specification.

2.0

REFERENCE DOCUMENTS Reference has also been made to the latest edition of the following standards, codes and specifications. The edition enforce at the time of floating the enquiry shall be termed as latest edition. a. ASTM D-149

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

b. ASTM D-257

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

c. ASTM D-543

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

d. ASTM D-570

: Standard Method of Test for Water Absorption of Plastics.

e. ASTM D-638

: Standard Method of Test for Tensile Properties of Plastics.

f. ASTM D-792

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

g. ASTM D-1238

: Test Method for Flow Rates of Thermoplastics by Extrusion

h. ASTM D-1525

: Test Method for Vicat Softening Temperature of Plastics

i. ASTM D-1603

:

Test Method for Carbon Black in Olefin Plastics

j. ASTM D-1693

: Test Method for Environmental Stress Cracking of Ethylene Plastics

k. ASTM D-2240

: Test Method for Rubber Property Durometer Hardness

l. ASTM D-3895

:

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

m. ASTM G-42

: Tentative Methods for Cathodic Disbonding of Pipeline coatings Subjected to Elevated or Cyclic Temperatures.

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 3 of 34

Copyright GAIL – All rights reserved

n. API RP 5L1

: Recommended Practice for Railroad Transportation of Line pipe.

o. API RP 5LW

: Transportation of Line Pipe on Barges and Marine Vessels

p. DIN EN 10204

:

Metallic Products Types of Inspection Documents

q. DIN 53735

: Testing of Plastics: Determination of Melt Index of Thermoplastics.

r. ISO 8502-3

: Preparation of Steel Stubstrates before Application of Paints and Related Products -

Part 3 - Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method) s. ISO 9002

: Quality Systems : Specification of Production and Installation

t. ISO 11124

: Preparation of Steel Substrates Before Application of Paints and Related Products

u. SIS 055900

: Preparation of Steel Substrates before Application of Paints and Related Products -Visual Assessment of Surface Cleanliness

v. API 5L

:

w. ASME B31.8

Specification for Line Pipe

: Gas Transmission and Distribution Piping Systems.

x. ASME B31.4

: Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols

y. CSA Z245.20-98

: External Fusion Bond Epoxy Coating for Steel Pipe.

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.

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 4 of 34

Copyright GAIL – All rights reserved

3.2

Plant equipment, machinery and other facilities shall be in first class operating condition to at least meet the job requirements of quality and production. Worn out and improvised plants are not acceptable.

3.3

The CONTRACTOR shall, at his own responsibility and cost, provide and prepare all necessary area for the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other temporary installation. For each area, CONTRACTOR shall provide necessary agreements as required with the land owner(s) / relevant Authorities, and, on work completion, to clean and pay settlement and claims for damages, as applicable.

3.4

The CONTRACTOR shall at its own responsibility and cost, provide for water and power supply and other utilities and consumables and obtain authorization regarding access roads and other permits required for the execution of works conforming to all the requirements of the governing Authorities.

3.5

The CONTRACTOR shall at its own expense provide a fully equipped laboratory and test facilities with adequate inventory to carry out tests required for the procedure qualification and regular production. Outside testing for qualification and regular production is not acceptable to COMPANY.

3.6

The CONTRACTOR shall be fully responsible for adherence to all statutory regulations applicable for handling and disposal of the hazardous chemicals during the coating works.

3.7

The CONTRACTOR shall be responsible for obtaining all statutory approvals / clearances from relevant Authorities including Pollution Control Board, as applicable for the coating plant(s).

4.0

MATERIALS

4.1

The three layer coating system shall comprise of a powder epoxy primer, polymeric adhesive and a polyethylene 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 GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 5 of 34

Copyright GAIL – All rights reserved

certificates. a. Epoxy Powder: i.

Gel Time

ii. Cure time iii. Moisture content iv. Thermal Characteristics (Tg1, Tg2 , ∆H) b. Adhesive: i. Specific Gravity ii. Melt Flow Rate iii. Vicat Softening Point c. Polyethylene: i. Melt Flow Rate ii. Specific Gravity iii. Vicat Softening Point iv. Moisture Content v. Oxidative Induction Time In case of failure of any of the above tests in a batch, that batch of material shall be tested for all other tests required as per para 5.3.1 and 5.3.2 including the tests which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating. 4.4

All materials to be used shall be supplied in sealed, damage free containers and shall be suitably marked with the following minimum information: a. Name of the Manufacturer b. Type of Material c. Batch Number d. Place and Date of Manufacture e. Shelf Life/Expiry Date (if applicable) f. Quantity All materials noted to be without above identification shall be deemed suspect and shall be rejected by COMPANY. Such materials shall not be used for coating and shall be removed from site and replaced by CONTRACTOR at his expense.

4.5

CONTRACTOR shall ensure that all coating materials are properly stored in accordance with the Manufacturer's recommendation at all times, to prevent damage and deterioration in quality prior to use.

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 6 of 34

Copyright GAIL – All rights reserved

4.6

CONTRACTOR shall be required to use all materials on a date received rotation basis, i.e. first in- first used basis.

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

5.1

The coating shall be able to withstand a maximum in service operating temperature of (+)650C and shall conform to 'S’ Type of coating as per DIN 30670. In addition, in open storage the coating must be able to withstand a temperature of at least (+)80°C, without impaling its serviceability and properties specified.

5.2

The top coat polyethylene used shall be a black readymade compound, fully stabilized against Influence of ultraviolet reaction (i.e. sunlight), oxygen in air and heat (due to environmental temperature as specified above). No appreciable changes shall occur during exposure to such environments up to at least a period of 6000 hours. The CONTRACTOR shall submit certificate from Manufacturer in this regard.

5.3

Properties Properties of coating system and coating material shall comply the requirements indicated in subsequent paragraphs. In case the coating / material properties are tested as per test methods / standards other than specified herein below, the same may be accepted provided the test procedures and test conditions are same or more stringent than the specified.

5.3.1

Properties of Epoxy Powder and Adhesive CONTRACTOR shall choose such a brand of epoxy powder and adhesive that will achieve the functional requirements and properties of coating system as specified in para 5.1 and 5.3.3 of this specification respectively. Epoxy powder properties shall be as per CSA Z245.20.98. The colour of epoxy powder shall be either green or dark red or any other colour approved by COMPANY except grey colour. Copolymer grafted adhesive shall have the following properties: SI. No.

5.3.2

Properties

Unit

Requirement

Test Method

g/10 minutes

1 .0 min.

ASTM D1238

a.

Melt Flow Rate (190°C/2.16kg)

b.

Vicat Softening Point

°C

100 min.

ASTM D1525

c.

Specific Gravity

-

0.926 min.

ASTM D 792

Requirement

Test Method

Properties of Polyethylene Compound SI. No.

GAIL (INDIA) LTD NEW DELHI

Properties

Unit

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 7 of 34

Copyright GAIL – All rights reserved

a.

Tensile Strength @ + 25° C

N/mm2

17 min.

ASTM D 638

b.

Melt Flow Rate (190DC/2.16kg)

9/10 minutes

0.25 min.

ASTM D 1238 or DIN 53735

c.

Specific Gravity @ + 25°C

-

0.926 min. (MDPE) 0.941 min. (HDPE)

ASTM D 792

d.

Hardness @ + 25 °C

Shore D

50 min.

ASTM D 2240

e.

Water Absorption, 24 hours, @ + 25 °C

%

0.05 max.

ASTM D 570

f.

Volume Resistivity @ + 25°C

Ohm-cm

1016min.

ASTM D 257

g

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

Volts/ mm

30,000 min.

ASTM D 149

h.

Vicat

°C

110 min.

ASTM D 1525

i.

Elongation

%

600 min.

ASTM D 638

j-

Oxidative Induction Time in Oxygen at 220°C, Aluminum pan, no screen

Minutes

10

ASTM D3895

k.

Environmental Stress Crack Resistance (ESCR) (for F 50) : -Medium DensityCondition "C” -High DensityCondition "B"

l.

5.3.3

Softening Point

Carbon Black Content

300 Hours

ASTM D1693 300

%

2 min.

ASTM D 1603

Properties of Coating System

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 8 of 34

Copyright GAIL – All rights reserved

SI. No.

Properties

Unit

Requirement

Test Method

Bond Strength (using Type 2 Test Assembly a. i.e. Dynamometer) . @20+/-5°C . @65+/-5°C

Kg/cm

8.0 min 5.0 min

DIN 30670

Impact Strength (Min. of 30 impacts on b. body along the length. No breakdown allowed when tested at 25 Kv)

Joules per mm of coating thickness

7 min

DIN 30670

c.

Indentation Hardness @23+/-2°C @70+/-2°C

mm

0.2 max 0.3 max

DIN 30670

d.

Elongation at Failure

%

300 min.

DIN 30670

e.

Coating Resistivity (*)

Ohm - m2

10 8 min.

DIN 30670

-

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

DIN 30670

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

DIN 30670

f.

Heat Ageing (*)

9-

Light Ageing (*)

-

h.

Cathodic Disbondment @ + 65° C after 30 days @ + 65°C after 48 hrs

mm radius of disbondment (**)

I

Degree of Cure of Epoxy. Percentage Cure, ∆H. ∆Tg

GAIL (INDIA) LTD NEW DELHI

15 max. ASTM G42 7 max.

% C

0

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

95 +3/-2

CSA Z 245.20-98(***)

DOCUMENT No. S-04-02-005

REV-0 Page 9 of 34

Copyright GAIL – All rights reserved

(*) Test carried out in an independent laboratory of national / international recognition on PE top coat is also acceptable. (**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G42. (***) Temperature to which the test specimens are to be heated during cyclic heating shall however be as per the recommendations of epoxy powder manufacturer. 6.0

MEASUREMENT AND LOGGING CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipe coating including pipe number, heat number, diameter, length, wall thickness, defects, coating number, batches of materials, sampling, testing, damages, repairs, rejects and any other information that COMPANY considers to be relevant and required for all incoming bare pipes and COMPANY approved outgoing coated pipes as applicable. CONTRACTOR'S documentation shall be designed to ensure full traceability of pipe and coating materials through all stages of coating and testing. CONTRACTOR shall submit this information in the form of a report at the agreed intervals. The above data shall also be provided in MS ACCESS format in Compact Disc (CD). CONTRACTOR shall provide one Computer Terminal to COMPANY Representative for monitoring/tracking of the above. The CONTRACTOR shall also submit the material balance details to COMPANY for information at the end of each shift.

7.0

COATING PROCEDURE AND QUALIFICATION

7.1

Upon award of the CONTRACT, the CONTRACTOR shall submit within two (2) weeks, for COMPANY approval, a detailed report in the form of bound manual outlining, but not limited to, the following:

a.

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

b.

Details of the equipment available to carry out the coating works including surface preparation, epoxy powder application and its recycling system, adhesive & polyethylene extrusion, moisture control facilities available for coating materials.

c.

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

d.

Details of chemical pre-treatment facilities including process control and inspection equipment for phosphoric acid wash, de-ionised water wash and chromate wash.

e.

Facilities in the yard for unloading, handling, transport, production, storage, stockpiling, loading of bare and coated pipes and warehouses for storage of other coating materials.

f.

Plant Organization Chart and availability of manpower including coating specialist

g.

Details of utilities/facilities such as water, power, fuel, access roads and communication etc. GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 10 of 34

Copyright GAIL – All rights reserved

After approval has been given by COMPANY, no change in plant set-up shall be made. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.2

At least four (4) weeks prior to the commencement of production coating, a detailed procedure of the CONTRACTOR'S methods, material proposed, etc., shall be formulated by the CONTRACTOR and submitted for COMPANY approval in the form of a bound manual. The procedure shall include, but not limited to, the following information and proposals: a. Pipe inspection at the time of bare pipe receipt. b. Steel surface preparation, including preheating, removal of steel defects, method of pipe cleaning, dust removal, abrasive blast cleaning and surface profile; methods of measurements and consumables. c. Complete details of chemical pre-treatment viz phosphoric acid wash, de-ionized water wash, and chromate wash including product data sheets, health and safety sheets and manufacturer's recommended application procedure. d. Pipe heating, temperatures and control prior to epoxy application. e. Complete details of raw materials including current data sheets showing values for all the properties specified together with quality control and application procedure recommendations from manufacturer(s). f. Application of FBE powder, adhesive and polyethylene, including characteristics, temperature, line speed, application window, curing time, etc. g. Quenching and cooling, including time and temperature. h. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting formats, including instrument and equipment types, makes and uses, etc i.

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

j.

Details of instrument and equipment calibration methods including relevant standards and examples of calibration certificates.

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

Pipe handling and stock piling procedure.

m. Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification. n. Complete details of test certificate for raw material including test methods and standard used. o. Test certificates from PE compound manufacturer for tests for thermal aging, coating resistively and aging under exposure to light. These test certificates shall not be older than three years.

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 11 of 34

Copyright GAIL – All rights reserved

p. Health, Safety and Environment Plans. q. Storage details of coating materials and chemicals. r. Continuous temperature monitoring at various stages of coating Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of the above procedure from COMPANY. No change in the procedure shall be made after approval has been given by the COMPANY. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.3

Prior to start of production, the CONTRACTOR shall, at his expense, carry out a coating PQT for each pipe diameter on max. wall thickness, for each type of pipe, for each coating material combination, and for each plant; to prove that his plant, materials, and coating procedures result in a quality of end product conforming to the properties stated in clause 5.3, relevant standards, specifications and material manufacturer's recommendations. CONTRACTOR shall give seven (7) working days notice to witness all procedures and tests. A batch representing a normal production run, typically 15 pipes, shall be coated in accordance with the approved coating procedure and the coating operations witnessed by COMPANY Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers. At least 5 (five) test pipes shall be selected by COMPANY Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. All tests shall be witnessed by the COMPANY Representative. Out of 5 (five) test pipes, 1 (one) pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers shall be included. Remaining 4 (four) test pipes shall have all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a part of coating operations as detailed subsequently.

7.4

Qualification of Procedures

7.4.1

Epoxy Powder Application & Recycling During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of monitoring system, line speed vs coating thickness, etc. shall be established. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be recorded during the PQT. Also, the CONTRACTOR shall remove samples of reclaimed powder from the reclamation system. These samples of reclaimed powder shall be subject to a detailed visual examination, thermal analysis and moisture content tests. The properties of the reclaimed powder shall be within the range specified by the Manufacturer of epoxy powder. In case the properties of the reclaimed powder are out of the range specified by the Manufacturer, CONTRACTOR shall not use the reclaimed powder during the regular production.

7.4.2

Pipe Pre-heating The CONTRACTOR shall establish the temperature variation due to in-coming pipe

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 12 of 34

Copyright GAIL – All rights reserved

temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc. and document the same during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and recording system including alarm/hooter shall be demonstrated to the COMPANY Representative. 7.4.3

Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance with the requirements of this specification. The ratio of shots to grits shall be established during procedure qualification testing, such that the resultant surface profile is not dished and rounded. The qualification shall be performed through a visual inspection, measurement of roughness and check of the presence of dust in the abrasive blast cleaned pipe surface.

7.4.4

Chemical Pre-treatment

7.4.4.1

Phosphoric Acid Wash followed by De-ionised Water Wash The procedure to apply the chemical pre-treatment viz. phosphoric acid wash followed by de-ionised water wash shall be In accordance with the recommendations of the manufacturer and shall result in intended cleaning requirements of this specification. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the cleanliness/temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line speed vs. dwell time, rinsing procedure, testing & control, rectificatory measures, drying procedure etc. shall be clearly established during PQT. Also the quality of the deionised water shall be established during PQT.

7.4.4.2

Chromate Treatment The procedure to apply the chromate treatment shall be in accordance with the recommendations of the manufacturer. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line speed, pipe heating after chromating and time limit within which the pipe to be heated, testing & control, rectificatory measures, shall be clearly established during PQT.

7.4.5

Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, preheating pipe surface temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature and flow rate of co-polymer adhesive and polyethylene, etc. and the same shall be recorded. These values shall be complied with during regular production.

7.5

Qualification of Applied Coating

7.5.1

Tests on pipe coated partly with epoxy and partly with epoxy & adhesive Layers

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 13 of 34

Copyright GAIL – All rights reserved

a. Degree of Cure Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. b. Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12 o'clock positions. The thickness shall comply with the specified thickness requirements. c. Adhesive layer Thickness Adhesive layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12'o clock positions. The thickness shall comply with the specified thickness requirements. d. Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall be set to exceed 5 v/micron of epoxy thickness specified for the portion coated only with epoxy layer. e. Adhesion Test i. Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. ii. Adhesion of FBE shall also be separately determined at ambient temperature at two locations by the "St Andrews Cross" method and the test shall comply with the specified requirements. f. 2.5° Flexibility Test 2.5° Flexibility test shall be carried out on the epoxy coated pipe at test temperature of 0°C. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. g. Cross-section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98. Table 4. 7.5.2

Tests on pipes coated with all three layers a. Bond Strength: Three test pipes shall be selected for bond strength tests. On each of the selected pipes, three bond strength test shall be performed for each specified temperature I.e. one at each end and one in the middle of the pipe and specified

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 14 of 34

Copyright GAIL – All rights reserved

requirements shall be complied with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65 mm. None of these samples shall fail. b. Impact Strength: Three test pipes shall be selected for impact strength test and the test shall meet the specified requirements. c. Indentation Hardness: Two samples for both temperatures from all pipes shall be taken. If any one of these samples fail to satisfy the specified requirements, then the test shall be repeated on four more samples. In this case, none of the samples shall fail. d. Elongation at failure: Six samples each from three coated pipes i.e. 18 samples In all shall be tested and the test shall comply the specified requirement. Only one sample per pipe may fail. e. Cathodic Disbondment Test: Two CD tests shall be carried out for the total lot of test pipes having all three layers. One test shall be carried out for 30 days duration and another test for 48 hours duration. The tests shall comply the specified requirement. Whenever Procedure Qualification is necessitated for different pipe size with same coating material combination, 48 hours test only be conducted. 30 days CD test is not mandatory in this case. f. Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in para 10.4, (b). g. Coating Thickness Measurement All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be as per para 10.3. h. Air Entrapment One sample each from pipe body and on weld (if applicable) shall be taken from all four coated pipes and the specified requirements shall be complied with. i. Degree of Cure Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. 7.5.3

Inspection of all test pipes All pipes shall be subject to the following Inspections:

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 15 of 34

Copyright GAIL – All rights reserved

a.

Surface cleanliness, surface roughness measurements and dust control immediately after second abrasive blast cleaning and salt test immediately after De-ionised water wash.

b.

pH of pipe surface before and after phosphoric acid wash.

c.

visual inspection of chromate coating.

d.

Visual inspection of finished coating, cut back dimension, internal/external cleanliness, end sealing and bevel inspection. Acceptance criteria for all inspection and testing shall be as specified in this specification.

7.6

After completion of the qualification tests and inspection as per para 7.4 and 7.5 above, the CONTRACTOR shall prepare and Issue to COMPANY for approval a detailed report of the above tests and inspection including test reports/certificates of all materials and coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall commence production coating.

7.7

On successful completion of PQT, coating of all five (5) test pipes shall be removed and completely recycled as per the approved coating procedure specification, at CONTRACTOR'S expense. Remaining pipes will be accepted by COMPANY provided they meet the requirements of this specification and need not be stripped and re-cycled.

7.8

The CONTRACTOR shall re-establish the requirements of qualification and in a manner as stated before or to the extent considered necessary by COMPANY, in the event of, but not limited to, the following: 

Every time there is a change in the previously qualified procedure.



Every time there is a change in the manufacturer and change in formulation of any of the raw materials and change in location of raw material manufacture.



Every time the coating yard is shifted from one location to the other or every time the critical coating equipments (induction heater, epoxy spray system, extruder, etc) are shifted.



Any change In line speed during coating application



Any time when in COMPANY'S opinion the properties are deeded to be suspect during regular production tests.

7.9

COMPANY reserves the right to conduct any or all the test required for qualification through an independent laboratory or agency at the cost of CONTRACTOR when in COMPANY's opinion, the results are deemed suspect. COMPANY's decision shall be final.

8.0

PIPE SURFACE PREPARATION

8.1

Unless specified otherwise, the pipes shall be supplied free from mill applied oils but GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 16 of 34

Copyright GAIL – All rights reserved

may be subject to contamination occurring during transit. 8.2

Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall ensure that all defects, flats and other damages have been repaired or removed. The CONTRACTOR shall also remove marking stickers, if any, present within the pipe. Record shall be kept of such marking on the stickers to ensure traceability of pipe after coating.

8.3

Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond or coating quality shall be removed prior to coating application. Contaminants may be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning.

8.4

All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasive blast cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blast cleaning units to achieve the specified surface cleanliness and profile. After first abrasive blast cleaning, chemical pre-treatment with phosphoric acid solution as per para 8.6 shall be carried out prior to second abrasive blast cleaning. However at the option of CONTRACTOR, chemical pre-treatment with phosphoric acid solution as per para 8.6 may be carried out after the second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection system to ensure total removal of dust generated during blast cleaning from the pipe surface. The equipment used for abrasive blast cleaning shall meet the specified requirements and shall be free from oil, water soluble salts and other forms of contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be checked for condensed water and oil at the start of each shift and emptied and cleaned regularly. During abrasive blast cleaning, the metallic abrasive shall be continuously sieved to remove "fines" and "contaminants" and the quality checked at every four hours. Abrasives used for blast cleaning shall comply ISO11124

8.5

Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into the pipe during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively the CONTRACTOR may link the pipes suitably together to prevent the entry of any shot/grit into the pipe.

8.6

Chemical Pre-treatment with Phosphoric Acid Solution

8.6.1

All pipes shall be provided chemical pre-treatment with phosphoric acid solution. 10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used to remove all soluble salts and other soluble contaminants. The CONTRACTOR shall provide data sheets and supporting documentation for the phosphoric acid to be used. The documentation shall verify that the phosphoric acid is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification.

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 17 of 34

Copyright GAIL – All rights reserved

8.6.2.1

The pipe temperature immediately prior to the phosphoric acid treatment shall be in the range of 450 to 750C. Phosphoric acid treatment shall be followed immediately by washing with de-ionised water. Deionised water used shall conform to the following requirements:

SI.No.

Properties

Unit

Requirement

a.

Turbidity

NTU

1 max.

b.

Conductivity

μmho/cm

5 max.

C

Hardness

d.

Total Alkalinity as CaC03

mg/l

2 to 3

e.

Chloride as CI"

mg/l

1 max.

f.

Sulphate as SO4

mg/i

1 max.

g.

pH

-

-

Nil

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 GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 18 of 34

Copyright GAIL – All rights reserved

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.

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 19 of 34

Copyright GAIL – All rights reserved

8.11

Upon Completion of the blasting operations, the quality control supervisor shall accept the pipe for further processing or return for re-blasting after removal of defects/imperfections. In case imperfections are considered detrimental to the coating quality, the same shall be reported to COMPANY'S Representative for final decision on rejection or re-blasting / removal of defects. Re-blasting / removal of defects or returning pipe to the yard shall be at the CONTRACTOR'S cost. COMPANY'S Representative, in additions, reserves the right to initiate any of the above actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal finish, etc.

8.12

In order to ensure that pipe with defects are not processed further, provisions shall be available to lift the pipes from inspection stand.

8.13

Chemical Pre-treatment with Chromate Solution

8.13.1

Following completion of abrasive blast cleaning, all pipe surface shall be chemically pre-treated with a10% strength chromate solution.

8.13.2

The CONTRACTOR shall provide data sheets and supporting documentation for the chemical to be used. The documentation shall verify that the chemical is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification.

8.13.3

The chemical pre-treatment shall be applied fully in accordance with the chemical suppliers' Instructions and in a manner that ensures 100% uniform coverage of the pipe surface without introducing surface contamination.

8.13.4 The CONTRACTOR shall check that the concentration of the chemical pre- treatment solution remains within the range recommended by the chemical manufacturer for the pipe coating process. The concentration shall be checked at the make up of each fresh solution and once per hour, using a method approved by the chemical manufacturer. The CONTRACTOR shall also ensure that the chemical pre-treatment solution remains free from contamination at all times. Recycling of chemical pretreatment solution is not permitted. 8.13.5

The CONTRACTOR shall ensure that the temperature of the substrate is maintained between 40°C and 80°C and the chromate solution temperature does not exceed 60°C or as recommended by the manufacturer.

8.13.6

The chromate coating shall be smooth, even, free from runs, drips or excessive application and lightly adherent with no flaking of the coating. The chromate coated steel must be thoroughly dried immediately after application and shall be achieved by boiling off any residual solution on the surface.

8.14

The total allowable elapsed time between completion of the blasting operations and commencement of the pre-coating and heating operations shall be such that no detectable oxidation of the surface occurs. Relative humidity readings shall be recorded every half an hour during the blasting operations in the immediate vicinity of the operations. The maximum elapsed time shall not exceed the duration given

GAIL (INDIA) LTD NEW DELHI

3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

REV-0 Page 20 of 34

Copyright GAIL – All rights reserved

below:

Relative Humidity %

Maximum elapsed time

>80

2 hours

70 to 80

3 hours

22 mm

Figure 2 Type A

Alloy Steel, Stainless Steel Up to 10 mm & Low Temp. Carbon > 10 mm & Up to 25 mm Steel

Figure 4

> 25 mm

Figure 3 Type A

Figure 5 Type A Figure 6 Type A

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

I.G.C Test for Stainless Steel

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR PIPES

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 3 of 9

Copyright GAIL – All rights reserved

1.13

Specified heat treatment for carbon steel and alloy steel and solution annealing for stainless steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot shall be restricted to maximum two by approved repair procedure.

1.14

For black or 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.

2.0

IBR PIPES

2.1

IBR Documentation :

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 ≥ Sc

SA

≥

Where, SA

:

Allowable stress at the working metal temperature

Et

:

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

Sc

:

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

Sr

:

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR PIPES

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 4 of 9

Copyright GAIL – All rights reserved

SA (psi) Temp 500 (oF) Material

600

650

700

750

800

850

900

950

1000

1050

1100

A335 Gr. P 11

17200

16700

16200

15600

15200

15000

14500

12800

9300

6300

4200

2800

A691 Gr. 1 ¼ Cr

18900

18300

18000

17600

17300

16800

16300

15000

9900

6300

4200

2800

A 335 Gr. P22 / A691 Gr. 2 ¼ Cr

17900

17900

17900

17900

17900

17800

14500

12800

10800

7800

5100

3200

Note:

2.2

SA values given above are as per ASME B 31.3 – 1999. Values shall be as per the latest edition prevailing.

For carbon steel pipes under IBR the chemical composition shall conform to the following : Carbon (max)

:

0.25 %

Others (S, P, Mn)

:

As prescribed in IBR regulation.

The chemical composition as indicated in this cluse is not applicable for pipes other than IBR services. 3.0

HYDROSTATIC TEST Refer Annexure – I

4.0

MARKING AND DESPATCH

4.1

All pipes shall be marked in accordance with the applicable codes, standards and specifications. In addition the purchase order number, the item code & special 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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR PIPES

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 5 of 9

Copyright GAIL – All rights reserved

4.4

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

4.5

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

4.6

Rust preventive used on machined surfaces to be welded shall be easily removable with 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: Plain end Bevel end Threaded end

: : :

Plastic Cap Wood, Metal or Plastic Cover Metal or plastic threaded cap

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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR PIPES

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 6 of 9

Copyright GAIL – All rights reserved

Page 1 of 3 ANNEXURE – I 3.0

HYDROSTATIC TEST

3.1

All pipes shall be hydrostatically tested.

3.2

The mill test pressure shall be as follows :

3.2.1 Seamless, E.R.W. & Spiral welded : a)

Carbon Steel Material Std.

ASTM A 106 Gr. B API 5L Gr. B, Seamless API 5L, E.R.W. API 5L, Spiral ASTM A333 Gr.3 & 6, Seamless ASTM A333 Gr.3 & 6, E.R.W b)

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

Seamless Alloy Steel Material Std.

ASTM A335 Gr.. P1, P12, P11, P22, P5, P9 ASTM A268 TP 405, TP 410 c)

Test Pressure Std.

Test Pressure Std. ASTM A 530 ASTM A 530

Seamless Stainless Steel Material Std.

ASTM A312 Gr. TP 304, 304L, 304H, 316, 316L, 316H, 321, 347 d) Seamless Nickel Alloy Material Std. ASTM B161 UNS No. 2200 ASTM B165 UNS No. 4400 ASTM B167 UNS No. 6600 ASTM B407 UNS No. 8800 API 5L Gr. B, Seamless API 5L, E.R.W. API 5L, Spiral ASTM A333 Gr.3 & 6, Seamless ASTM A333 Gr.3 & 6, E.R.W GAIL (INDIA) LTD NEW DELHI

Test Pressure Std. ASTM A 530

Test Pressure Std. ASTM B161 ASTM B165 ASTM B167 ASTM B407 API 5L API 5L API 5L ASTM A 530 ASTM A 530

TECHNICAL NOTES FOR PIPES

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 7 of 9

Copyright GAIL – All rights reserved

Page 2 of 3 e)

Welded Nickel Alloy Material Std.

Test Pressure Std.

ASTM B725 UNS No. 2200, 4400 ASTM B517 UNS No. 6600 ASTM B514 UNS No. 8800

ASTM B725 ASTM B517 ASTM B514

3.2.2 Electric Fusion Welded a)

Carbon Steel & Alloy Steel E.FS.W (16” & above) Material Std.

Test Pressure Std.

API 5L Gr. B ASTM A671 Gr.CC65, 70 (Cl.32) ASTM A672 Gr.C60, 65, 70 (Cl.12, 22) ASTM A671 Gr.CF60, 65, 66, 70 (Cl.32) ASTM A691 Gr.1/2 Cr, 1Cr, 1 ¼ Cr, 2 ¼ Cr, 5Cr, 9Cr (Cl.42) b)

P = 2ST / D S = 90% of SMYS Except for API 5L Gr. B S = 85% of SMYS For API 5L Gr. B T = Nominal Wall Thickness D = O.D of Pipe

Stainless Steel E.FS.W (2” to 6”) :

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 2” 3” 4” 6”

Pipe Schedule : 10S Material Material Gr.1 Gr.2 100 80 80 60 80 50 65 35

GAIL (INDIA) LTD NEW DELHI

Pipe Schedule : 40S Material Material Gr.1 Gr.2 155 130 155 130 155 130 90 75

TECHNICAL NOTES FOR PIPES

Pipe Schedule : 80S Material Material Gr.1 Gr.2 230 190 230 190 230 190 155 130

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 8 of 9

Copyright GAIL – All rights reserved

Page 3 of 3 c)

Stainless Steel E.FS.W (8” and above) Material Std.

Test Pressure Std.

P = 2ST/D ASTM A358 TP 304L, 304, 304H, 316L, 316, 316H, 321, 347 (Classes 1, 3 S = 85% of SMYS T = Nominal Wall Thickness & 4) D = O.D. of pipe P = 2ST/D ASTM A358 TP 304L, 304, 304H, 316L, 316, 316H, 321, 347 (Classes 2 & S = 72% of SMYS T = Nominal Wall Thickness 5) D = O.D. of pipe 3.2.3 Carbon Steel Pipes to IS Standards: Material Std. IS 1239 IS 3589

GAIL (INDIA) LTD NEW DELHI

Test Pressure Std. IS 1239 IS 3589

TECHNICAL NOTES FOR PIPES

TECHNICAL NOTES S – 05 – 02 – 001

REV- 0 Page 9 of 9

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR PIPELINE VALVES

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 1 -of 17

Copyright GAIL – All rights reserved

CONTENTS S. NO.

TITLE

1.0

GENERAL

2.0

DOCUMENTATION

3.0

DESIGN AND CONSTRUCTION

4.0

OPERATION

5.0

INSPECTION AND TESTING

6.0

RADIOGRAPHY OF CAST VALVES

7.0

IBR CERTIFICATION

8.0

MARKING

9.0

DESPATCH

10.0

ATTACHMENTS

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 2 -of 17

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR VALVES 1.0

GENERAL

1.1

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

1.2

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

1.3

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

2.0

DOCUMENTATION

2.1

Vendor shall submit the following with the offer:

2.1.1

Manufacturer’s complete descriptive and illustrative catalogue / literature.

2.1.2

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 3 -of 17

Copyright GAIL – All rights reserved

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.

3.0

DESIGN AND CONSTRUCTION

3.1

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

3.2

All flanged valves shall have flanges integral (except forged valves) with the valve body. Flange face finish shall be normally specified in the valve specification sheet as serrated finish, 125 AARH etc. The interpretation for range of face finish shall be as follows: Stock Finish Serrated Finish / Smooth Finish/ 125 AARH AARH Extra Smooth Finish / 63 AARH

3.3.

:

1000 µ in AARH max.

:

Serrations with 125 to 250 µ in

:

32 TO 63 µ in AARH

For all weld end valves with bevel end as per ASME B16.25 the contour of bevel shall be as follows:

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 4 -of 17

Copyright GAIL – All rights reserved

3.4

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

Min. Hardness of Groove (BHN)

Carbon Steel

140

1%Cr to 5%Cr

150

Type 304, 316. 321, 347

160

Type 304L, 316L

140

3.5

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

3.5.1

Unless specified otherwise in the data sheet all check valves 3” & above (except in 900#, 1500# & 2500# rating) shall have a drain boss at location “G” (Refer Fig.No.1 of ASME B16.34). A tapped drain hole with plug shall be provided as per ASME B16.34. Threads shall be as per ASME B1.20.1 (Taper) NPT.

3.5.2

Wherever check valve disc assembly is supported from the cover of the check valves the following shall be ascertained. i)

Positive location /positioning of cover must he provided to ensure correct alignment of the valve disc.

ii)

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

3.5.3

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

Following valve bypass requirements shall be met:

3.7.1

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

:

On sizes 26” and above

ANSI 300 Class

:

On sizes 16” and above

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 5 -of 17

Copyright GAIL – All rights reserved

ANSI 600 Class

:

On sizes 6” and above

ANSI 900 Class

:

On sizes 4” and above

ANSI 1500 Class

:

On sizes 4” and above

ANSI 2500 Class

:

On sizes 3” and above

3.7.2

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

3.7.3

By-pass valve shall be a globe valve. The sizes shall be as under: On main valve ≤ 4”

:

1/2” or more

On main valve > 4” but < 10” :

3/4” or more

On main valve > 10”

1” or more

:

The by-pass arrangement shall be as specified in Specification Sheet No.12 - 13. 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: GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 6 -of 17

Copyright GAIL – All rights reserved

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

Ball/ Plug/ Butterfly Valves:

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. GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 7 -of 17

Copyright GAIL – All rights reserved

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:

150#

8” & below

Floating ball

10” & above

Trunnion mounted

4” & below

Floating ball

6” & above

Trunnion mounted

300#

600# & above

1.5” & below Floating ball 2” & above

Trunnion mounted

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:

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 8 -of 17

Copyright GAIL – All rights reserved

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 Valves

Totally enclosed bevel gear in grease case with grease nipples / plugs.

For Ball / Plug / Butterfly Valves

Totally enclosed helical worm or combination of helical worm and spur gear in grease case with grease nipples / plugs.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES S – 05 – 02 – 002

REV 0 Page - 9 -of 17

Copyright GAIL – All rights reserved

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.

5.0

INSPECTION AND TESTING

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: 1. 2. 3. 4. 5.

Visual and dimensional inspection. Review of material test certificates. Any mandatory or supplementary test. Hydrostatic test on 10% valves selected on random basis. Strip check is required for 1 % of total ordered quantity of valves (min. 1 No.) against each specification lot.

Cast Steel Valves: 1. 2. 3. 4. 5.

Visual and dimensional inspection. Review of material test certificates. Review of radiographic reports or any other NDT tests wherever applicable as per data sheet. Any mandatory or supplementary test. Hydrostatic test 100% for body, 10% other test.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 10 -of 17

Copyright GAIL – All rights reserved

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 size in the lot.

highest

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’

6.0

RADIOGRAPHY OF CAST VALVES

6.1

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

Material

All

Rating

Size Range

Radiography

150#

24” and below

NIL

26” and above*

100%

16” and above

NIL

18” and above

100%

All Sizes

100%

300#

600# & above

*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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 11 -of 17

Copyright GAIL – All rights reserved

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.

7.0

IBR CERTIFICATION

7.1

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

7.2

For SW/ BW end carbon steel valves under IBR, the chemical composition shall conform to the following: Carbon (Max)

:

0.25%

Others (S, P, Mn)

::

As per IBR regulations

The above composition is not valid for non-IBR valves. 7.3

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

7.4

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

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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 12 -of 17

Copyright GAIL – All rights reserved

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 Flange Face Bevelled End SW & SCRD.End

: : :

Wood or Plastic Cover Wood or Plastic Cover Plastic Cap

9.5

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

9.6

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

9.7

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

10.0

ATTACHMENTS (Cut out the irrelevant attachments) Bypass Piping Arrangement Special Requirement for Low temperature and Cryogenic Valves Data Sheet Format for Torque Values of MOVs

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 13 -of 17

Copyright GAIL – All rights reserved

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. GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 14 -of 17

Copyright GAIL – All rights reserved

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.

2.0

Qualification Criteria 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. 2.1

Cryogenic Test Vendors to furnish copies of cryogenic test certificate for tests conducted as per details given below: i).

Shall be as per BS: 6364.

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 15 -of 17

Copyright GAIL – All rights reserved

rating and material. In case of austenitic SS any one grade would qualify for all other grades of austenitic SS. iv). 2.2

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.

Reference List 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.

2.3

Post Order Testing Procedure i).

ii).

Before conducting post order testing, vendor shall submit the following for approval: a).

Test procedure (as per BS 6364).

b).

Cross-section drawing of the valve with material of construction.

c).

Schematic of test rig (as per BS 6364) with complete details.

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.

iii).

In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the test(s) conducted after receipt of order, the owner reserves the right to invoke any of the provisions of the purchase order including cancellation of the purchase order at the risk and cost of vendor,

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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 16 -of 17

Copyright GAIL – All rights reserved

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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR VALVES

TECHNICAL NOTES

REV 0

S – 05 – 02 – 002

Page - 17 -of 17

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DATASHEET FORMAT DATSHEET FOR TORQUE VALUES OF MOV

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 1 of 7

Copyright GAIL – All rights reserved

1.0

GENERAL

1.1

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

1.2

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

1.3

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

1.4

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

1.5

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

1.6

Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as follows:

Material

Wall Thickness

Carbon Steel (Except Low Upto 22 mm Temp. Carbon Steel) > 22 mm Alloy Steel, Stainless Steel & Low Temp. Carbon Steel

1.7

Wall Contour Figure 2 Type A Figure 3 Type A

Upto 10 mm

Figure 4

> 10 mm & Upto 25 mm

Figure 5 Type A

>25 mm

Figure 6 Type A

Welded Fittings:

1.7. 1 All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. Welds shall be ground smooth at least 25 mm from the ends. 1.7.2

For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be manufactured with the addition of filler metal.

1.7.3

Welded tees shall not be of fabricated (stub-in) type. GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 2 of 7

Copyright GAIL – All rights reserved

1.7.4

All welded fittings shall be normalised & 100% radiographed by X-ray on all welds made by fitting manufacturers & also on the parent materials.

1.7.5

Welded pipes employed for manufacture of fittings shall be made by automatic welding only.

1.7.6

All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative tolerance of 0.3 mm.

1.7.7

Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after weld repairs.

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

Stainless Steel Fittings:

1.8.1

All stainless steel fittings shall be supplied in solution heat treated condition.

1.8.2

Solution annealing for stainless steel fittings shall be carried out again after weld repairs.

1.8.3

For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as per the following: ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”. Or ASTM A 262 Practice “E” with acceptance criteria of “no cracks as observed from 20X magnification” & “microscopic structure to be observed from 250X- magnification

1 .8.4 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (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:

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 3 of 7

Copyright GAIL – All rights reserved

Serrated Finish

:

Serrations with 250 to 500 µ in AARH

Smooth Finish/125 AARH

:

Serrations with 125 to 250 µ in AARH

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:

1.19

Welded Pipe Employed For Manufacture of Welded Fittings.

Test Criteria

ASTM A671 Gr. C65,70 (C1.32) ASTM A672 Gr. C60,65,70 (Cl. 12, 22) ASTM A671 Gr. CF6O,65,70,66 (Cl.32) ASTM A691 Gr. ½Cr, 1Cr, 1’%Cr, 2’ACr, 5Cr, 9Cr (Cl.42)

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

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

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

ASTM B725

ASTM B725

ASTM B517

ASTM B517

ASTM B514

ASTM B514

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 4 of 7

Copyright GAIL – All rights reserved

1.20

Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable in forging materials (upto 1½”) and wrought fitting materials (above 1½”) also in the corresponding material grades.

1.21

Abbreviations for ends of swages and nipples shall be as follows: PBE TBE TOE TSE TLE

: : : : :

Plain Both Ends Threaded Both Ends Threaded One End Threaded Small End Threaded Large End

2.0

IBR REQUIREMENTS

2.1

IBR Documentation Required:

2.1.1

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

2.1.2

For materials 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

SA: Allowable stress at the working metal temperature. Et: Yield point (0.2% proof stress at the working metal temperature) Sc: The average stress to produce elongation of 1% (creep) in 100000 hrs at the working metal temperature. Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperature.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 5 of 7

Copyright GAIL – All rights reserved

Note: SA values given above are from ASME B31.3-1996. Values shall be as per the latest edition prevailing. 2.2

For carbon steel fittings described “IBR” chemical composition shall conform to the following: Carbon (max)

:

0.25 %

Others (S, P, Mn)

:

As prescribed in IBR regulations

The above composition is not valid for Non-IBR fittings. 3.0

MARKING AND DESPATCH

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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 6 of 7

Copyright GAIL – All rights reserved

3.9

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

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

TECHNICAL NOTES S-05-02-003

REV-0 Page 7 of 7

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS

TECHNICAL NOTES S-05-02-004

REV- 0 Page 1 of 5

Copyright GAIL – All rights reserved

1.0

GENERAL

1.1

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

1.2

Testing

1.2.1 Test reports shall 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: Stock Finish Serrated Finish/125 AARH 63 AARH

GAIL (INDIA) LTD NEW DELHI

: : :

1000 μ in AARH max. Serrations with 125 to 250 μ in AARH 32 TO 63 μ in AARH

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS

TECHNICAL NOTES S-05-02-004

REV- 0 Page 2 of 5

Copyright GAIL – All rights reserved

1.8

Galvanised flanges shall be coated with zinc by hot dip process conforming to IS 4736/ ASTM A153.

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 MR01-75 unless otherwise specified. 1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition. 1.14

I.G.C. Test for Stainless Steels:

1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges 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. GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS

TECHNICAL NOTES S-05-02-004

REV- 0 Page 3 of 5

Copyright GAIL – All rights reserved

1.16

AWWA C207 flanges shall be hub type.

2.0

IBR REQUIREMENTS

2.1

IBR Documentation:

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

:

0.25%

Others (S, P, Mn)

:

As prescribed in IBR Regulation

The chemical composition as indicated in this clause is not applicable for flanges other than IBR. 3.0

SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE

3.1

Method of Manufacture

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

Impact Test

3.2.1 For all carbon steels and alloy steels with wall thickness over 19 mm, Charpy-V Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-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 ftlb) per set of 3 specimens, with a minimum of 19J (15 ft-lb). 4.0

MARKING AND DESPATCH

4.1

All items shall be legibly and conspicuously stamped in accordance with the requirements of applicable ASME, API and MSS Standards. In addition, GAIL item code, purchase order number & special conditions like “IBR”, “CRYO”, “NACE” ‘H2” etc. shall also be stamped.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS

TECHNICAL NOTES S-05-02-004

REV- 0 Page 4 of 5

Copyright GAIL – All rights reserved

4.2

All items coming under the purview of “IBR”, “CRYO” , “NACE” & “H2’(hydrogen) shall be painted in red stripes, light purple stripes, canary yellow stripes & sea green stripes (25 mm width) respectively for easy identification.

4.3

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

4.4

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

4.5

All items shall 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: Flange face Bevelled end Threaded end Socket welding end

: : : :

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

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 Specification for Positive Material Identification (PMI) at Vendor’s Works – S-14-02-001

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP RINGS

TECHNICAL NOTES S-05-02-004

REV- 0 Page 5 of 5

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR BOLTS AND NUTS (PIPING)

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BOLTS AND NUTS

TECHNICAL NOTES S-05-02-005

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR BOLTS AND NUTS

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. GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BOLTS AND NUTS

TECHNICAL NOTES S-05-02-005

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

14.

Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested as per supplementary requirement S3 of ASTM A193.

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.

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR BOLTS AND NUTS

TECHNICAL NOTES S-05-02-005

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

TECHNICAL NOTES FOR GASKETS

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR GASKETS

TECHNICAL NOTES S-05-02-006

REV- 0 Page 1 of 3

Copyright GAIL – All rights reserved

1.0

GENERAL

1.1

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

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

1.3.3

For Spiral wound material following shall be furnished: a.

Manufaturer’s test certificate for filler material and spiral material as per the relevant material specifications.

b.

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

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.

1.3.5

Refer ‘Inspection and Test Plan for 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:

GAIL (INDIA) LTD NEW DELHI

TECHNICAL NOTES FOR GASKETS

TECHNICAL NOTES S-05-02-006

REV- 0 Page 2 of 3

Copyright GAIL – All rights reserved

1.8

a.

Sizes 26” and above

b.

Class 900 and above

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

Maximum Hardness (BHN)

Soft Iron

90

Carbon Steel

120

5 Cr., ½ Mo

130

Type 304, 316, 321, 347

140

Type 304L, 316L

120

1.9

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

1.10

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

1.11 All items shall be inspected and approved by GAIL Inspector or any other agency authorized by GAIL. 1.12 Any additional requirements specified with.

in the requisition, shall be fully complied

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 (I) (O) CAF GRAFIL

: : : :

GAIL (INDIA) LTD NEW DELHI

Inner Ring Outer Ring Compressed Asbestos Fibre Grafoil Filler

TECHNICAL NOTES FOR GASKETS

TECHNICAL NOTES S-05-02-006

REV- 0 Page 3 of 3

Copyright GAIL – All rights reserved

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 1 of 16

Copyright GAIL – All rights reserved

Abbreviations:

PMI

:

Positive Material Identification

NDT

:

Non Destructive Testing

P&ID :

Process and Instrumentation Diagram

A.S.

:

Alloy Steel

C.S.

:

Carbon Steel

C.I.

:

Cast Iron

S.S.

:

Stainless Steel

LTCS :

Low Temperature Carbon Steel

NACE :

National Association of Corrosion Engineers

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 2 of 16

Copyright GAIL – All rights reserved

CONTENTS Sl. No.

Description

1.

SCOPE

2.

SCOPE OF WORK OF CONTRACTOR

3.

BASIS OF WORK

4.

FABRICATION

5.

ERECTION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 3 of 16

Copyright GAIL – All rights reserved

1.0

SCOPE This specification covers general requirements of fabrication and erection of above ground and trench piping systems at site. The specification covers the scope of work of contractor, basis of work to be carried out by contractor and standards, specifications and normal practice to be followed during fabrication and erection by the contractor.

2.0

SCOPE OF WORK OF CONTRACTOR Generally the scope of work of contractor shall include the following:

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.

2.2

a.

Pipes (All sizes and schedule)

b.

Flanges (All sizes, types & Pressure ratings).

c.

Fittings (All sizes, types and schedule)

d.

Valves (All sizes, types and Ratings)

e.

Gaskets (All sizes, types & Ratings)

f.

Bolts, Nuts or M/C Bolts (All types)

g.

Expansion Joint/Bellows (All types)

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.

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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 4 of 16

Copyright GAIL – All rights reserved

2.3

Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips, cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, teeposts including erection of spring supports and sway braces.

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. 2.4.3 Fabrication of swage nipples as and when required. 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. 2.4.6 Fabrication of stub-in connection with or without reinforcement. 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-inCharge 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. GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 5 of 16

Copyright GAIL – All rights reserved

2.13 Providing insert plates from concrete structures and repair of platform gratings around pipe openings. 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. 3.0

BASIS FOR WORK

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. 3.1.3 Approved Process licensors standards and specifications. 3.1.4 Drawings, sketches and documents prepared by contractor duly approved by Engineer-in- Charge (such as isometrics of small bore piping and offsite piping etc.) 3.1.5 Approved construction job procedures prepared by Contractor as stipulated in 2.16 3.1.6 GAIL specifications/documents as below: a.

Process and Instrument Diagram.

b.

Piping Materials Specification

c.

Piping support standards.

d.

Line list

e.

Piping support indices (only in offsite), if supports are not shown in plan.

f.

Standard specification of Non-destructive Requirement of Piping

g.

Welding specification charts for piping classes

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 6 of 16

Copyright GAIL – All rights reserved

h.

Standard Specification for Pressure Testing of Erected Piping System

i.

Welding specification for fabrication of piping

j.

Any other GAIL or OTHER specifications attached with Piping Material Specification or special condition of contract (such as standard for cement lining of pipe, standard of jacketed piping, standard for steam tracing, Dimensional Tolerances etc.)

k.

Procedure for storage, preservation and positive identification of materials at Contractors works / stores.

3.1.7 Following codes, standards and regulations a.

ASME B 31.3

:

Process Piping

b.

ASME Sec. VIII

:

Code for unfired pressure vessel.

c.

IBR Regulations

d.

IS: 823

:

Code for procedure for Manual Metal Arc welding of Mild Steel (for structural steel).

e.

NACE Std.

:

Code for Sour Services material requirements 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

4.1

Piping Material 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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 7 of 16

Copyright GAIL – All rights reserved

have been fabricated I erected. Material traceability is to be maintained for AS., SS., NACE, LTCS, material for Hydrogen service and other exotic materials by way of transferring heat number, etc. (hard punching) as per approved procedure. This shall be in addition to colour coding for all piping materials to avoid mix-up. For the purpose of common understanding the construction job procedure, to be submitted by the contractor, shall include proposal for - Maximizing prefabrication, inspection and testing at fabrication shop with minimum field joints. - Positive material identification, handling, storage & preservation. 4.2

Dimensional Tolerances Dimensional tolerances for piping fabrication shall be as per GAIL Standard. The Contractor shall be responsible for working to the dimensions shown on the drawings. However, the Contractor shall bear in mind that there may be variations between the dimensions shown in the drawing and those actually existing at site due to minor variations in the location of equipments, inserts, structures etc. To take care of these variations “Field Welds” shall be provided during piping fabrication. An extra pipe length of 100 mm over and above the dimensions indicated in the drawing may be left on one side of the pipe at each of the field welds. During erection, the pipe end with extra length at each field weld shall be cut to obtain the actual dimension occurring at site. Isometrics, if supplied may have the field welds marked on them. However, it is the responsibility of the Contractor to provide adequate number of field welds. In any case no extra claims will be entertained from the Contractor on this account. Wherever errors I omissions occur in drawings and Bills of Materials it shall be the Contractor’s responsibility to notify the Engineer-in-Charge prior to fabrication or erection.

4.3

IBR Piping

4.3.1 Contractor shall be supplied generally with all drawings for steam piping falling under the purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor shall carry out the fabrications, erection and testing of this piping as per requirements of Indian Boiler Regulations and to the entire satisfaction of the local Boiler Inspector. The Contractor shall also get the approval of IBR inspector for all fabrication and testing done by him at his own cost. All certificates of approval shall be in proper JBR forms. 4.3.2 Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by the contractor at his own cost. 4.4

Pipe Joints The piping class of each line specifies the type of pipe joints to be adopted. In general, joining of lines 2” and above in process and utility piping shall be accomplished by butt-welds. Joining of lines 1-1/2” and below shall be by socket GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 8 of 16

Copyright GAIL – All rights reserved

welding/butt welding/threaded joints as specified in “Piping Material Specifications”. However, in piping 1-1/2” and below where socket welding/ threaded joints are specified butt - welds may be used with the approval of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only applicable for non-galvanized piping without lining. Flange joints shall be used at connections to Vessels, Equipment’s, Valves and where required for ease of erection and maintenance as indicated in drawings. 4.5

Butt Welded and Socket Welded Piping End preparation, alignment and fit-up of pipe pieces to be welded, welding, preheating, post-heating and heat treatment shall be as described in the welding specification and NDT specification.

4.6

Screwed Piping In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.l NPT as required to match threads on fittings, valves etc. All other piping shall have threads as per ANSI B2.l, tapered unless specified otherwise. Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed. Threading of pipes shall be done preferably after bending, forging or heat treating operations. If this is not possible, threads shall be gauge checked and chased after welding heat treatment etc. During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with thread sealant and the joint tightened sufficiently for the threads to seize and give a leak proof joint. Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and made up to full thread engagement before seal welding.

4.7

Flange Connections All flange facings shall be true and perpendicular to the axis of pipe to which they are attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation is shown in the drawing. Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the flange, shall be done before welding it to the pipe.

4.8

Branch Connections Branch connections shall be as indicated in the piping material specifications. For end preparation, alignment, spacing, fit-up and welding of branch connections refer welding specifications. Templates shall be used wherever required to ensure accurate cutting and proper fit-up. For all branch connections accomplished either by pipe to pipe connections or by using forged tees the rates quoted for piping shall be inclusive of this work. GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 9 of 16

Copyright GAIL – All rights reserved

Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc. 4.9

Bending Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be used. 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.

4.10 Forging and forming 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. 4.11 Mitre Bends and Fabricated Reducers 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 4piece 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. 4.12 Cutting and Trimming of Standard Fittings & Pipes 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. 4.13 Galvanized 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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 10 of 16

Copyright GAIL – All rights reserved

4.14 Jacketed Piping The Jacketing shall be done in accordance with GAIL Specification or Licensors specification as suggested in material specification or special condition of contract. Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at shop by Contractor. Position of jump over and nozzles on the jacket pipes, fittings etc. shall be marked according to pipe disposition and those shall be prefabricated to avoid damaging of inner pipe and obstruction of jacket space. However, valves, flow glasses, in line instruments or even fittings shall be supplied as jacketed. 4.15 Shop Fabrication / Pre-Fabrication The purpose of shop fabrication or pre-fabricationm is to minimise work during erection to the extent possible. Piping spool, after fabrication, shall be stacked with proper identification marks, so as facilitate their withdrawal at any time during erection. During this period all flange (gasket contact faces) and threads shall be adequately fabricated by coating with a removable rust preventive. Care shall also be taken to avoid any physical damage to flange faces and threads. 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. 4.16.2 Spun Concrete Lining 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. 4.16.3 Fabrication of pipes from plate Pipes shall be fabricated at site as and when required as per the specifications attached and the actual Piping Material Specification. 5.0

ERECTION

5.1

Cleaning of Piping before 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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 11 of 16

Copyright GAIL – All rights reserved

specification or isometric or line list. SS jacketed piping requiring pickling shall be pickled to remove oxidation and discolouring due to welding. 5.2

Piping Routing No deviations from the piping route indicated in drawings shall be permitted without the consent of Engineer-in-Charge. Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings shall be strictly followed as these clearances may be required for the free expansion of piping / equipment. No deviations from these clearances shall be permissible without the approval 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.

5.3

Cold Pull 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

Expansion Joints/ Bellows Installation of Expansion Joints/Bellows shall be as follows:

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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 12 of 16

Copyright GAIL – All rights reserved

5.5.3

5.5.4

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.

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.

b.

Expansion Joints stop blocks shall be carefully removed after hydrostatic testing. Angles welded to the flanges or weld ends shall be trimmed by saw as per manufacturer’s instructions and the flanges or weld ends shall be ground smooth.

5.5.5 a.

b.

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. 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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 13 of 16

Copyright GAIL – All rights reserved

c.

5.6

Hydrostatic Testing of the system having Expansion Joint shall be performed with shipping lugs in position. These lugs shall be removed after testing and certification is over.

Flange Connections 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. Temporary protective covers shall be retained on all flange connections of pumps, turbines, compressors and other similar equipments, until the piping is finally connected, so as to avoid any foreign material from entering these equipments. 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.

5.7

Vents and Drains 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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 14 of 16

Copyright GAIL – All rights reserved

Fabrication of stem extensions, locking arrangements and interlocking arrangements of valves (if called for), shall be carried out as per drawings/ instructions of Engineerin- Charge. 5.9

Instruments Installation of in-line instruments such as restriction orifices, control valves, safety valves, relief valves, rotameters, orifice flange assembly, venturimeters, flowmeters etc. shall form a part of piping erection work. 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.

5.10 Line Mounted Equipments / Items 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. 5.11 Bolts and Nuts 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. 5.12 Pipe Supports 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. GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 15 of 16

Copyright GAIL – All rights reserved

No pipe shoe I cradle shall be offset unless specifically shown in the drawings. 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 restraints have been installed correctly. - Clearances have been maintained as per support drawings. - Insulation does not restrict thermal expansion. - All temporary tack welds provided during erection have been fully removed. - All welded supports have been fully welded.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF PIPING

SPECIFICATION

REV-0

S – 05 – 02 – 011

Page 16 of 16

Copyright GAIL – All rights reserved

STANDARD SPECIFICATION FOR NON DESTRUCTIVE EXAMINATION OF PIPING

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 1 of 16

Copyright GAIL – All rights reserved

Abbreviation :DP/LP :

Dye Liquid Panetrant

MP

:

Magnetic Particle

CS

:

Carbon Steel

AS

:

Alloy Steel

SS

:

Stainless Steel

ASTM :

American Society for Testing & Materials

ASME :

American Society of Mechanical Engineers

IBR

:

Indian Boiler Regulations

PM

:

Piping Material Specification

ASNT :

American Society of Non-Destructive Testing

PCN :

Personal Certification in Non-Destructive Testing

PWHT:

Post Weld Heat Treatment

UST

Ultrasonic Testing

:

HS&E :

Safety, Health & Environment

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 2 of 16

Copyright GAIL – All rights reserved

CONTENTS

SL. No.

TITLE

1.

GENERAL

2.

VISUAL EXAMINATION

3.

NON DESTRUCTIVE EXAMINATIONS

4.

TABLE –I

5.

ULTASONIC WELD EXAMINATION

6.

INSPECTION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 3 of 16

Copyright GAIL – All rights reserved

1.

GENERAL

1.1

SCOPE The specification covers the General Requirements for Non- Destructive Examinations of shop and field fabricated piping.

1.2

RELATED CODES AND ENGINEERING STANDARDS Referred codes/ standards are as follows. Latest edition of following codes/standard shall be followed :

a. b. c. d. e. f. g. h. 1.3

ASME Boiler and Pressure Vessels codes, Section V & VIII (Div.-1) including Addenda ASME B 31.3 ANSI B 31.8 ASME B16.5 ASME B 16.34 PCN/ ASNT PMS In addition to that all general specification dealing with welding and fabrication of various equipment shall apply. 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.

1.4

NDE COMPANY CERTIFICATION All Non Destructive Examination (NDE) Contractor’s contracted by the OWNER or working for fabricators or Contractor’s carrying out work on the OWNER behalf shall have in place an up-to-date Quality Control Manual and Code of Practice which shall cover the following: i)

All aspects of NDE of which the CONTRACTOR, SUB-CON TRACTOR is qualified.

ii)

Current resumes of all presently employed personnel including their certifications (PCN, ASNT, CGSB or equivalent).

iii)

All proposed specific NDE procedure,

A registered copy of QC manual shall be made available to OWNER and shall be GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 4 of 16

Copyright GAIL – All rights reserved

reviewed and approved by the OWNER quality assurance personnel prior to services being used. Updates to the Manual shall be forwarded to the registered holder as they become available. 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. 2.0

VISUAL INSPECTION 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 shall be visually inspected wherever accessible in accordance with the following requirements: 1 2 3

4 5

Internal misalignment Cracks or lack of fusion Incomplete penetration (for Incomplete penetration (for other than 100% Radiography butt-weld)

Surface porosity and exposed slag inclusions (4.7mm. Nom Wall thickness and less) Concave root surface (SLICK UP)

6 7 8 9 10

Weld ripples irregularities Lack of uniformity in bead width Lack of uniformity of leg length Unevenness of Bead

11

Overlap

Weld Undercutting

GAIL (INDIA) LTD NEW DELHI

1.5 MM or Less None permitted. Depth shall not exceed the lesser of 0.8 MM or 0.2 times thickness of thinner component joined by butt-weld. The total length of such imperfections shall not exceed 38 MM in any 150 MM of weld length. Not permitted For single sided welded joints concavity of the root surface shall not reduce the total thickness of joint including reinforcement to less than the thickness of the thinner of the components being joined. 2.5 MM or Less 2.5 MM or Less 2.5 MM or Less 2.0 MM or Less 0.8 MM or 1/4 thickness of thinner components joined by butt weld, whichever is less. (shall be smooth finished)

1.5 mm or less STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 5 of 16

Copyright GAIL – All rights reserved

12 13

Bead Deflection

2.5 mm or less

External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused with and shall merge smoothly into the component surfaces. The height of the lesser projection of external weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the following limits : Wall thickness of thinner component Weld reinforcement or internal weld joined by butt weld (MM) protrusion (MM) Max

6.4 and under Over 6.4 – 12.7 Over 12.7 – 25.4 Over 25.4 14 15

1.6 3.2 4.0 4.8

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

Flattening: Flattening of a bend, as measured by difference between the nominal outside diameter and minimum or maximum diameter at any cross section shall not exceed 5% of the nominal outside diameter of pipe.

16

Reduction of Wall Thickness: Reduction of wall thickness of a bend, as measured by difference between the nominal thickness and minimum thickness shall not exceed 10% of the nominal wall thickness of pipe. Welds having any imperfections which exceed the limitations specified in various clauses shall be repaired by welding, grinding or overlaying etc.

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: MATERIAL

NO. OF TIMES OF REPAIR WELDING

1.0 2.0

CS UP TO 300# CS ABOVE 300#

3.

NON DESTRUCTIVE EXAMINATION

3.1

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

3.2

Welds between dissimilar 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): a) b) c)

3 OR LESS 2 OR LESS

High Pressure Severe Cyclic Low Temperature

GAIL (INDIA) LTD NEW DELHI

: : :

Classes 900# & above As defined by ASME B 31.3 Below temperature of -45 Deg C.

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 6 of 16

Copyright GAIL – All rights reserved

3.4

3.5 3.5

d)

Critical Service

:

e) f)

High alloys High Temperature

: :

Hydrogen, Oxygen, NACE, Caustic, Chlorine & such other critical services. 5 Cr. & above for all pressure classes Above 500 Deg.C

EXTENT OF INSPECTION AND TESTING a) Piping systems which are designed and constructed in accordance with ASME Standard B 31.3, Chemical Plant and Petroleum Refinery Piping, shall be radiographed as per Table - I. 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.

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. CONTRACTOR shall not deviate from any requirement of this specification without written approval to do so from OWNER

3.6

No exemption permitted in regards to full HS&E compliance.

3.7

Open drains vents or other open ended line shall be leak tested only.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 7 of 16

Copyright GAIL – All rights reserved

4.

TABLE-I (with applicable Notes)

TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION INSPECTION CLASS: I IN SP N. CL AS S

1

SERVICE

CATEGO RY ‘D’ FLUID SERVICE

MATERIA L (NOTE3)

CARBON STEEL

AUSTENE TIC SS HDPE CUPRO NICKEL

TEMP DEG C

PRESS CL. B16.5/ B16.34

0-186

(-) 29 TO 86 (-) 20 TO 50 (-) 29 TO 60

150 # UP TO 10.55 KG/ 2 CM

PIPING CLASS

A3A, A3Y, J2A, J3A, J5A, A4Y, A5Y A3K A1Z, A4Z, A5Z

TYPE OF EXAM.

TYPE OF WELD EXAMINATION

GIR TH BUT T WEL D

SCK T WEL D (NO TE2)

ATTA CHME NT WELD

FAB. BRNC H WELD (NOTE 1)

FAB MITR / RED

a) VISUAL

100 %

100 %

100%

100%

100%

b) LP (NOTE 4, 6, 9)

---

---

---

10%

10%

REMARKS FOR ABOVE TABLE: 1.

LP TEST NOT APPLICABLE TO NON-METALLIC CLASSES

2.

MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 8 of 16

Copyright GAIL – All rights reserved

TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.) INSPECTION CLASS: II IN SP N. CL AS S

II

SERVICE

a) ALL SERVICES COVERED UNDER INSPECTION CLASS-I BUT EXCEEDING CATEGORYD PR./TEMP. LIMITATION.

b) ALL SERVICES EXCEPT COVERED UNDER CLASS – I BUT NONTOXIC, NOT SUBJECTED TO SEVERE CYCLIC CONDITIONS

MATE RIAL (NOTE -3)

TEM P DEG C

PRESS CL. B16.5/ B16.34

-29 TO 400 CS

150 # UP TO 10.55 KG/ 2 CM

CS (IBR)

PIPING CLASS

A1A, A6A, A7A, A8A, A9A, A11A, A13A, A15A, A20A, A32A, A33A, A33Y

A2A

TYPE OF EXAM.

a) VISUAL

b) RADIOGRAP HY (NOTE 5, 6)

c) MP/LP/ (NOTE 4,6, 10,11)

d) HARDNESS

TYPE OF WELD EXAMINATION

GIR TH BUT T WEL D

SOC KT WEL D (NO TE2)

ATTA CHME NT WELD

FAB. BRNC H WELD (NOTE I)

FAB .MIT R/ RED

100 %

100 %

100%

100%

100%

10%

---

---

---

50%

---

10%

---

10%

50%

NO TE7

NO TE7

NOTE7

NOTE7

NOTE -7

REMARKS FOR ABOVE TABLE: 1.

FOR A2A IBR SERVICE NOTE-8 IS ALSO APPLICABLE

2.

FOR A33A & A33Y FIRE WATER SERVICE, NOTE-12 IS ALSO APPLICABLE.

3.

EXTENT OF HARDNESS TEST FOR A11A IS 100%.

4.

MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 9 of 16

Copyright GAIL – All rights reserved

TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.) INSPECTION CLASS: III IN SP N. CL AS S

III

SERVICE

a) TOXIC, NONLETHAL & FLAMMAB LE b) FLAMMAB LE / NON FLAMMAB L & TOXIC / NONTOXIC; NOT SUBJECT TO SEVERE CYCLIC CONDITIO NS

ALL GENERAL SERVICES EXCEPT THOSE SUBJECT TO SEVERE CYCLIC CONDITIO NS.

MATE RIAL (NOTE -3)

CS

TEM P DEG C

ABO VE (-)29

PRES S CL. B16.5/ B16.3 4

PIPING CLASS

TYPE OF EXAM.

GIRTH BUTT WELD

SCK T WEL D (NO TE 2)

ATTA CHME NT WELD

FAB. BRNC H WELD (NOTE 1)

FAB MITR / RED

100%

100 %

100%

100%

100%

20%

---

---

---

100%

c) MP/LP/ (NOTE 4,6, 11)

---

20%

---

20%

---

d) HARDNES S

NOTE7

NOTE

NOTE7

NOTE7

NOTE -7

150 # --a) VISUAL

KILLED CARBO N STEEL

CARBO N

(-) 45 TO 204

150# TO 600#

A4A, B4A, D4A b) RADIOGR APHY (NOTE 5, 6)

(-) 29 TO 427

TYPE OF WELD EXAMINATION

300# TO 600#

STEEL

CS (IBR)

B1A, B6A, B9A, B13A, B32A, D1A

-7

B2A, D2A

REMARKS FOR ABOVE TABLE: 1.

FOR IBR SERVICE B2A & D2A NOTE-8 IS ALSO APPLICABLE

2.

MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 10 of 16

Copyright GAIL – All rights reserved

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. UT testing shall be carried out : (i) As per ASME B31.3 and ASME Sec. V article 5. (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. (iv) Ultrasonic testing, in lieu of radiography, is acceptable only where radiography is not practicable e.g. branch connections

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.

Applicable Notes to Table-I 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.

3.

Unless specifically stated, all materials shall be for Non-IBR service. GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 11 of 16

Copyright GAIL – All rights reserved

4.

5.

Magnetic particle & the Liquid penetrant method of examination shall be in accordance with section-V of the ASME Boiler and Pressure Vessels Code, Article VII and VI respectively. The entire area of the accessible finished weld surface shall be examined. Selected root runs, subject to a maximum of 10%, before finished weld, may also be examined, at the discretion of the engineer-in-charge. a)

Wherever MP/LP testing is specified, either MP or LP test may be used. But wherever only MP test is specified, LP method of examination may be used only if MP examination is impractible in the field as concurred by GAIL sitein-charge.

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.

c)

When Liquid Penetrant examination is specified, the surface shall be free of peened discontinuities. Abrasive blast cleaning shall be followed by light surface grinding prior to liquid penetrant examination.

d)

Inspection shall be performed in the welds excluding those for which radiography has been done.

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.

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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 12 of 16

Copyright GAIL – All rights reserved

a)

6.

Radiographers supplied by the CONTRACTOR shall be certified to ASNT Level II, AWS QC] and as per AWS B1.10 (guide for nondestructive 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. “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)

In-process examination shall not be substituted for any required radiographic examination.

c)

Number of radiographs per one circumferential weld shall be as per ASME Sec. V Article 2 and 22.

When radiography or other non-destructive inspection is specified, acceptance criteria for repairs or defects shall be as follows: a)

In case of 100% examination, any unacceptable weld shall be repaired and reinspected.

b)

If required random examination reveals a defect requiring repair, then: b.1

Two additional 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).

b.2

If the group of items examined as required by b.1 above is acceptable, the item requiring repair shall be repaired or replaced and

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 13 of 16

Copyright GAIL – All rights reserved

reexamined as required and all items represented by this additional examination shall be accepted. b.3

If any of the items examined as required by b.1 above reveals a defect requiring repair, two further comparable items shall be examined for each defective item found by examination.

b.4

If all the items examined as required by b.3 are acceptable, the items requiring repair shall be repaired or replaced and reexamined as required, and all items represented by this further examination shall be acceptable.

b.5

Number of times repair welding could b done for the same weld before acceptance shall be as follows: Material

No. of times repair welding is allowed

C.S. upto 300# C.S. above 300# Killed Steel Low alloy steel Austenitic S.S. 3.5 Ni Steel Al & Al base alloy Cu & Cu base Alloy Others

3 2 2 2 2 2 2 2 2

less less less less less less less less less

b.6

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

b.7

If any of the items examined as required by b.4 above reveals a defect requiring repair, all items represented by these examination shall be either:  

7.

or or or or or or or or or

repaired or replaced and reexamined as required. Fully examined and repaired or replaced as necessary, and reexamined as necessary.

Hardness Test: a)

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

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 14 of 16

Copyright GAIL – All rights reserved

b)

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

c)

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

d)

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

e)

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

f)

Hardness test requirement not covered in b) & e) above shall be as per ASME B 31.3.

g)

The hardness limit applies to the weld and heat affected zone. Following hardness values shall be maintained:

BASE METAL GROUP CS CS (NACE) Cr 0.5% or less Cr 0.5% & up to 2% Cr 2.25% & up to 10% 18/8 SS (NACE) 8.

MAXIMUM HARDNESS (BHN/ RC) 238BHN/ RC22 200 BHN 225 BHN 225 BHN 241 BHN RC 22

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

Piping over 102 mm (4”) bore: 10% of welds made by each welder on a pipeline with a minimum of two welds per welder, selected at random, shall be subjected to radiography.

b)

Piping 102 mm (4”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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 15 of 16

Copyright GAIL – All rights reserved

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: If any test specification is unsatisfactory, two further weld specimens for retests shall be selected from the production welds and subjected to tests. In the event of failure of any retest specimens, the production welds carried out by this welder subsequent to the previous test shall be given special consideration.

9.

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

10.

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

11.

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

12.

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.

14.

DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR a) Electrode and welding consumables qualification records for the welding consumables tested and approved for the work. b) Batch test certificate, for the electrodes used, obtained from the Electrode Manufacturers. c) Proposed heat treatment chart procedure. d) Heat treatment chart. e) Weld joint tensile, hardness test, Impact test result. f) Welding procedure specification immediately after receipt of order. g) Welding procedure qualification records. h) Welder performance qualification records immediately after conducting welder qualification tests. i) Radiography procedure.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION OF “NON-DESTRUCTIVE EXAMINATION OF PIPING”

SPECIFICATION S – 05 – 02 – 012

REV- 0 Page 16 of 16

Copyright GAIL – All rights reserved

STANDARD SPECIFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 1 of 10

Copyright GAIL – All rights reserved

CONTENTS Sl. No.

Description

1.

SCOPE

2.

INSPECTION

3.

FLUSHING

4.

TESTING

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 2 of 10

Copyright GAIL – All rights reserved

Abbreviations PMI

:

Positive Material Identification

ppm

:

parts per million

S.S.

:

Stainless Steel

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 3 of 10

Copyright GAIL – All rights reserved

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-InCharge.

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: -

Proper piping material has been used.

-

PMI has been performed as per ‘Standard Specification for Positive Material Identification at Construction Sites, S-14-02-001.

-

Piping has been erected as per drawings and instructions of Engineer-InCharge.

-

All supports have been installed correctly.

3.0

Test preparations mentioned in this specification have been carried out.

FLUSHING Flushing of all lines shall be done before pressure testing. Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign material. Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure. For air flushing, the line / system will be 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.

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 4 of 10

Copyright GAIL – All rights reserved

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. Care shall be taken during flushing so as not to damage/spoil work of other agencies. Precautions shall also be taken to prevent entry of water/foreign matter into equipments, electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed. The contractor shall carry out all the activities required before, during and after the flushing operation, arising because of flushing requirements, such as but not limited to the following: Dropping of valves, specials, distance pieces, inline instruments and any other piping part before flushing. The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-In-Charge. These flanges shall be provided with temporary gaskets at the time of flushing. After flushing is completed and approved, the valve distance pieces, piping specials etc. shall be reinstalled by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where isolation is required during testing, only temporary gaskets shall be provided. Records in triplicate shall be prepared and submitted by the contractor for each piping system for the flushing done in the proforma provided/approved by the Engineer-in-Charge. 4.0

TESTING

4.1

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

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 5 of 10

Copyright GAIL – All rights reserved

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. 4.2

General Requirements / Test Preparation for Testing Testing shall be carried out with permanent gaskets installed unless specified otherwise or instructed by the Engineer-in-Charge. No pressure test shall be carried out against closed valve unless approved by the Engineer-in-Charge. The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence and programme, to enable him to be present for witnessing the test. The Contractor shall be fully responsible for making arrangements with the local boiler inspector to witness the tests for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the relevant IBR forms and furnished to the Engineer-in-Charge.

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 6 of 10

Copyright GAIL – All rights reserved

Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale, debris and other loose foreign materials. All piping systems to be hydrostatically tested shall be vented at the high points and the systems purged of air before the test pressure is applied. Wherever in the line any void exists due to any reasons, like absence of control valves, safety valves, check valves etc. it shall be filled with temporary spools. All joints welded, screwed or flanged shall be left exposed for examination during the test. Before pressuring the lines, each weld joint shall be cleaned by wire brush to free it from rust and any other foreign matter. Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted between the companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable design code. Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or wherever equipment or pipe spools have been recovered or disconnected prior to hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the piping system being tested. Pressure gauges used in testing shall be installed as close as possible to the lowest point in the piping system to be tested, to avoid overstressing of any of the lower portions of the system. For longer lines and vertical lines , two or more pressure gauges shall be installed at locations decided by the Engineer-in-Charge. For lines containing check valves any of the following alternatives shall be adopted for pressure testing: Whenever possible pressurize up-stream side of valve. Replace the valve by a temporary spool and reinstall the valve after testing. Provide blind on valve flanges and test the upstream and downstream of the line separately and remove the blind after testing. At these flanges, temporary gaskets shall be provided during testing and shall be replaced by permanent gaskets subsequently. For check valves in lines 1 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. Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of the fluid would overload the support. Retaining pins for spring GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 7 of 10

Copyright GAIL – All rights reserved

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. 4.3

Testing Media, Test Pressure and Test Pressure Gauges

4.3.1 Testing Media In general all pressure test shall be hydrostatic using iron free water, which is clean and free of silt. Maximum chlorine content in water for hydrostatic testing for S.S. piping shall be 15-20 ppm. Air shall be used for testing only if water would cause corrosion of the system or overloading of supports etc. in special cases as directed by Engineer-in-Charge. Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc. shall be used as the testing medium, with due consideration to the hazards involved. These test fluids shall be specified in the line list given to the contractor. 4.3.2 Test Pressure The hydrostatic! Pneumatic test pressure shall be as indicated in the line list or as per the instruction of Engineer-in-Charge. The selection of the piping system for one individual test shall be based on the following: Test pressure required as per line list. Maximum allowable pressure for the material of construction of piping. Depending upon the above requirements and based on construction progress, maximum length of piping shall be included in each test. 4.3.3 Test Pressure Gauge

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 8 of 10

Copyright GAIL – All rights reserved

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-inCharge shall check the accuracy of master pressure gauge used for calibration. 4.4

Testing Procedure

4.4.1 Hydrostatic Test All vents and other connections used as vents shall be left open while filling the line with test fluid for complete removal of air. In all lines for 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. Pressure shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system as soon as test pressure is reached and stabilised in the system. A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the required pressure. The pump shall be attended constantly during the test by an authorized person. The pump shall be isolated from the system whenever the pump is to be left unattended. Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be retested to the specified pressure after repair. Test period shall be maintained for a minimum of three hours. The pump and the piping system to be tested are to be provided with separate pressure indicating test gauges. These gauges are to be checked by the standard test gauge before each pressure test. Care shall be taken to avoid increase in the pressure due to temperature variation during the test. 4.4.2 Air Test

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 9 of 10

Copyright GAIL – All rights reserved

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). 4.5

Completion of Testing After the hydrostatic test has been completed, pressure shall be released in a manner and at a rate so as not to endanger personnel or damage equipments. All vents and drains shall be opened before the system is to be drained and shall remain open till all draining is complete, so as to prevent formation of vacuum in the system. After draining, lines / systems shall be dried by air. After testing is completed the test blinds shall be removed and equipment / piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop / circuit including equipments (except rotary equipments). Pressure test shall be considered complete only after approved by the Engineer-inCharge. 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.

4.6

Test Records Records in triplicate shall be prepared and submitted by the contractor for each piping system, for the pressure test done in the 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

GAIL (INDIA) LTD. NEW DELHI

S TANDARD SPECIFICATION FOR INSPECTION, FLUSHING & TESTING OF PIPING SYSTEMS

SPECIFICATION S – 05 – 02 – 013

REV- 0 Page 10 of 10

Copyright GAIL – All rights reserved

STANDARD SPECIFICATION FOR SHOP & FIELD PAINTING

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 1 of 49

Copyright GAIL – All rights reserved

CONTENTS 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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 2 of 49

Copyright GAIL – All rights reserved

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

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 3 of 49

Copyright GAIL – All rights reserved

1.0

GENERAL

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.

1.2

Wherever it is stated in the specification that a specific Material is to be supplied or a specific work is to be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any deviation from this standard without written appropriate authority will result in rejection of job.

2.0

deviation

permit

from

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

Extent of Works

2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting : a.

All un-insulated CS & AS equipment like columns, vessels, drums, storage tanks, heat exchangers, pumps, compressors, electrical panels and motors etc.

b.

All un-insulated carbon and low alloy piping fittings and valves (including painting of identification marks), furnace, ducts and stacks.

c.

All items contained in a package unit as necessary.

d.

All structural steel work, pipe, structural steel supports, walkways, hand rails, ladders, platforms etc .

e. f.

RCC / MS chimneys with or without refractory lining & Flare lines. Identification colour bands on all piping as required including insulated aluminum clad, galvanized, SS and non-ferrous piping.

g.

Identification lettering / numbering on all painted surfaces of equipment / piping insulated aluminum clad, galvanized, SS and non-ferrous piping.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 4 of 49

Copyright GAIL – All rights reserved

h.

Marking / identification signs on painted surfaces of equipment / piping for Hazardous service.

i.

Supply of all primers, paints and all other materials required for painting other than Owner's supply.

j.

Over insulation surface of equipments and pipes wherever required.

k.

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

l.

Repair work of damaged / pre-erection / fabrication shop primer and weld joints at field.

2.2.2 The following surfaces and materials shall not be painted unless otherwise specified: a.

Un-insulated austenitic stainless steel.

b.

Plastic and / or plastic coated materials.

c. 2.3

Non ferrous materials like Aluminum, Galvanized "piping", "gratings" and "Hand rails" etc. except G.I. Towers. Documents

2.3.1 The contractor shall perform the work in accordance with the following documents issued to him for execution of work. a.

Bill of quantities for Piping, equipment, machinery and structures etc.

b.

Piping Line List.

c.

Painting specifications including special civil defense requirement.

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.

3.0

CODES & STANDARDS

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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 5 of 49

Copyright GAIL – All rights reserved

3.2

IS-5

:

Colour coding

IS-101

:

Methods of test for ready mixed paints and enamels

IS-2379:1990

:

Indian Standard for Pipe line identification – colour Code

ASTM

:

American Standard test methods for paints and coatings

ASA A 13.1-1981

:

Scheme for Identification of piping systems: American National Standards Institution.

Surface Preparation Standards: Following standards shall be followed for surface preparations:

3.2.1 Swedish Standard : SIS-05 5900-1967 / ISO-8501-1-1988 (Surface preparations standards for Painting Steel Surfaces). This standard contains photographs of the various standards on four different degrees of rusted steel and as such is preferable for inspection purpose by the Engineer-in-Charge. 3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC – SP) 3.2.3 British Standards (Surface Finish or Blast-cleaned for Painting) BS-4232. 3.2.4 National Association of Corrosion Engineers, U.S.A. (NACE) 3.2.5 Various International Standards equivalent to Swedish Standard for surface preparation are given in Table-I. 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.

3.4

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

Instructions for storage to avoid exposure as well as extremes of temp.

b.

Surface preparation prior to painting.

c.

Mixing and thinning.

d.

Application of Paints and the recommended limit on time intervals between coats.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 6 of 49

Copyright GAIL – All rights reserved

4.0

EQUIPMENT

4.1

All tools, brushes, rollers, spray guns, abrasive material, hand cleaning and all equipments, scaffolding materials, shot / wet water blasting equipments & air compressors etc. required to suitable for the work and all in good order and shall be 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.

5.0

SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR AND DOCUMENTATION

5.1

General

/ power tools for abrasive blasting, be used shall be arranged by the

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: a.

Manual or hand tool cleaning

b.

Mechanical or power tool cleaning.

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-0559001967 / 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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 7 of 49

Copyright GAIL – All rights reserved

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. 5.2

Procedure of Surface Preparation

5.2.1 Blast Cleaning 5.2.1.1

Air Blast Cleaning

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. 5.2.1.2

Water Blast cleaning

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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 8 of 49

Copyright GAIL – All rights reserved

The water blast cleaned surface shall be comparable to SSPC-SP-12 / NACE NO. 5. The operation shall be carried out as per SSPC guidelines for water Blast cleaning. The indicative value for sand injection is as given below: Air

:

300 to 400 Cu. ft / min.

Water

:

5- 10 liters/min. with corrosion inhibitor

Sand

:

200 - 400 lbs / hr.

Nozzle

:

0.5 to 1" dia

Special equipments for water blast cleaning with abrasives now available shall be used. 5.2.2 Mechanical or Power tool cleaning Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or rotating steel wire-brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and / or washed by water or steam and thoroughly dried with compressed air jet before application of paint. 5.2.3 Manual or hand tool cleaning 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. Hand tool cleaning normally consists of the following: a.

Hand de-scaling and / or hammering

b.

Hand scraping

c.

Hand wire brushing

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. 5.3

Non compatible shop coat primer

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 9 of 49

Copyright GAIL – All rights reserved

The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event of use of primer such as zinc Rich epoxy, inorganic zinc silicate etc. as shop coat, the paint system shall depend on condition of shop coat. If shop coat is in satisfactory condition showing no major defects, the shop coat shall not be removed. The touch up primer and finishing coat(s) shall be identified for application by Engineer-in charge. 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. 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.

5.6

5.7

Coating Procedure and Application :

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. 5.7.6 Air spray application shall be in accordance with the following: 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

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 10 of 49

Copyright GAIL – All rights reserved

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. b.

Traps or separators shall be provided to remove oil and condensed water from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show no condensed water or oil.

c.

Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous mechanical agitation.

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. Any solvents left in the equipment shall be completely removed before applying paint to the surface being painted.

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.

h.

Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brush, daubers or sheepkins shall be used.

i.

All name plates, manufacturer's identification tags, machined surfaces, instrument glass, finished flange faces, control valve items and similar items shall be masked to prohibit coating deposition. If these surfaces are coated, the component shall be cleaned and restored to its original condition.

j.

Edges of structural shapes and irregular coated surfaces shall be coated first and an extra pass made later.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 11 of 49

Copyright GAIL – All rights reserved

k.

If spray gun shows choking, immediately de-choking procedure shall be followed.

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. Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have inbuilt agitator that keep the paint uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. A usually very small quantity of thinning is required before spray. Incase of High Build epoxy coatings (two pack), 30: 1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern. Ideally fluid hoses should not be less than 3/8" ID and not longer than 50ft to obtain optimum results. In case of gun choking, dechoking steps shall be followed immediately. 5.7.8 Brush application of paint shall be in accordance with the following : 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.

c.

Paint shall be applied into all corners.

d.

Any runs or sags shall be brushed out.

e.

There shall be a minimum of brush marks left in the applied paint.

f.

Surfaces not accessible to brushes shall be painted by spray, daubers, or sheepkin.

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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 12 of 49

Copyright GAIL – All rights reserved

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

Drying of coated Surfaces

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

Repair of damaged paint surface

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.  

Surface preparation shall be done as per procedure 5.9.2. One coat of F-9 shall be applied wherever damaged was observed on preerection / pre-fabrication / shop primer of inorganic zinc silicate coating (F9). F-9 shall not be applied if damaged area is not more than 5x5 cm.

5.10 PAINT APPLICATION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 13 of 49

Copyright GAIL – All rights reserved

5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface. 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.



Daily progress report with details of weather conditions, particular of applications, no of coats and type of materials applied, anomalies, progress of work versus programmed.



Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday detection, adhesion tests with signature of appropriate authority.



Particulars of surface preparation and paint application during trials and during the work.



Details of non-compliance, rejects and repairs.



Type of testing equipments and calibration.



Code and batch numbers of paint materials used.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 14 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 15 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 16 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 17 of 49

Copyright GAIL – All rights reserved

6.0

PAINT MATERIALS 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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 18 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 19 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 20 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 21 of 49

Copyright GAIL – All rights reserved

F-14: Specially formulated polyamine cured coal tar epoxy suitable for -450C to 125°C for application under insulation F-15: Two pack cold cured epoxy phenolic coating suitable for -450C to 125°C for application under insulation F-16: Epoxy siloxane Amercoat 738 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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 22 of 49

Copyright GAIL – All rights reserved

6.4

List of recommended manufacturers The paints shall conform to the specifications given above and the best quality in their products range of the manufacturers listed in Annexure-I.

7.0

PAINT SYSTEMS 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 & FINISH COATS COVERED IN TABLE NOS.7.0 to 15.0 PRIMERS P-2

:

Chlorinated Rubber Zinc Phosphate Primer

P-4

:

Etch Primer / Wash Primer

P-6

:

Epoxy Zinc Phosphate Primer

FINISH COATS / PAINTS F-2

:

Acrylic - Polyurethane finish paint

F-3

:

Chlorinated Rubber Finish Paint

F-6

:

High Build Epoxy finish coating

F-7

:

High Build Coal Tar epoxy coating

F-8

:

Self priming surface Tolerant High Build Epoxy coating

F-9

:

Inorganic Zinc Silicate coating

F-11

:

Heat resistant Synthetic medium based Aluminum paint

F-12

:

Heat resistant Silicone Aluminum paint

F-14

:

Specially formulated polyamine cured coal for Epoxy coating

F-15

:

Epoxy phenolic coating

F-16

:

Epoxy Siloxane coating: Amercoat 738

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 23 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 24 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 25 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 26 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 27 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 28 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 29 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 30 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 31 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 32 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 33 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 34 of 49

Copyright GAIL – All rights reserved

17.0 STORAGE: 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.

18.0 COLOUR CODE FOR PIPING: 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 clause6.0. 18.1 Colour coding scheme for pipes, equipment, machinery & structures:

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 35 of 49

Copyright GAIL – All rights reserved

18.2

The colour code scheme is intended for identification of the individual group of the pipeline. The system of colour coding consists of a ground colour and colour bands superimposed on it.

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. a.

At battery limit points

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 36 of 49

Copyright GAIL – All rights reserved

b.

Intersection points & change of direction points in piping ways.

c.

Other points, such as midway of each piping way, near valves, junction joints of service appliances, walls, on either side of pipe culverts.

d.

For long stretch / yard piping at 50M interval.

e.

At start and terminating points.

18.4 Identification Sign 18.4.1 Flow direction shall be indicated by an arrow in the location stated in Para b ,c & d and as directed by Engineer-in-Charge.

a,

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. 18.4.4 Size of arrow shall be either of those given in 18.5. 18.5 Colour Bands 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. Nominal pipe size figures are to be in inches. 18.5.2 Colour band(s) shall be arranged in the sequence shown in Table 18.1 and the sequence follows the direction of flow. The relative proportional width of the first colour band to the subsequent bands shall be 4: 1, minimum width of any band shall be as per Clause 18.5.1. 18.6

Whenever it is required by the Engineer-in-Charge to indicate that a pipeline carries a hazardous material, a hazard marking of diagonal strips of black and golden yellow as per IS:2379 shall be painted on the ground colour. GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 37 of 49

Copyright GAIL – All rights reserved

19.0 IDENTIFICATION OF VESSELS, PIPING ETC.: 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: Column & Vessels Pump, compressor and other machinery Piping

-

150 mm (high) 50 mm (high) 40 - 150 mm

19.2 Identification of storage tanks: The storage tanks shall be marked as detailed in the drawing. 20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS: 21.1

Following items shall be painted for camouflaging if required by the client. a. b. c. d.

20.2

All columns All tanks in offsites. Large Vessels Spheres

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-inCharge.

20.3 Method of camouflaging 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). 20.3.2 The patches should be asymmetrical and irregular. 20.3.3 The patches should be inclined at 30 Degree to 60 Degree to the horizontal. 20.3.4 The patches should be continuous where two surfaces meet at an angle. 20.3.5 The patches should not coincide with corners. 20.3.6 Slits and holes shall be painted in dark shades. 20.3.7 Width of patches should be 1 to 2 meters. 21.0 INSPECTION AND TESTING 21.1

All painting materials including primers and thinners brought to site by contractor

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 38 of 49

Copyright GAIL – All rights reserved

for application shall be procured directly from manufactures as per specifications and shall be accompanied by manufacturer's test certificates. Paint formulations without certificates are not acceptable. 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.

21.3

The painting work shall be subject to inspection by Engineer-in-Charge at all times. In particular, following stage wise inspection will be performed and contractor shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows: a.

Surface preparation

b.

Primer application

c.

Each coat of paint

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 . 21.4 Primer Application After surface preparation, the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence of inspector nominated by Engineer-inCharge. 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 GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 39 of 49

Copyright GAIL – All rights reserved

pinhole detector and positector whenever required for checking in case of immersion conditions. 21.7

Prior to application of paints on surfaces of chimneys, the thickness of the individual coat shall be checked by application of each coat of same paint on M.S. test panel. The thickness of paint on test panel shall be determined by using gauge such as 'Elkometer'. The thickness of each coat shall be checked as per provision of this specification. This shall be approved by Engineer-in-Charge before application of paints on surface of chimney.

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.

23.0 QUALIFCATION CRITERIA OF PAINTING 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. 24.0 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND MANUFACTURERS GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 40 of 49

Copyright GAIL – All rights reserved

Following procedure is recommended to be followed for approval of new manufacturers. 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.

24.2

Samples of coating materials should be submitted to the Govt. laboratory in sealed containers with batch no. and test certificate on regular format of manufacturer's testing laboratory. The sampling shall be certified and sealed by a certifying agency.

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. TEST

GAIL (INDIA) LTD NEW DELHI

ASTM TEST METHOD STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 41 of 49

Copyright GAIL – All rights reserved

DENSITY DIPPING PROPERIES

-

D 1475 D 823

DRYING TIME FLEXIBILITY HARDNESS

-

D 1640 D 1737 / D 522 D 3363

ADHESION ABRASION RESISTANCE DFT / COAT STORAGE STABILITY

-

D 2197 D 968 / D 1044 AS PER SSPC GUIDELINES D 1849

FILM CHARACTERSTICS

RESISTANCE TO HUMIDITY FOR 2000 HRS. SALT SPRAY FOR 2000 HRS ACCELERATED WEATHERING %Zn IN DFT 24.6

D 2247 B 117 D 822 G 53

Coating system for panel test shall be decided after discussion with GAIL.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 42 of 49

Copyright GAIL – All rights reserved

ANNEXURE-I LIST OF RECOMMENDED MANUFACTURERS INDIAN VENDORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Asian paints(1) Ltd. Berger Paints Ltd. Goodlass Nerolac paints Ltd. Jenson and Nicholson paints Ltd. & ChokuGu Jenson & Nicholson Ltd. Shalimar paints Ltd. Sigma coatings, Mumbai CDC Carboline Ltd. Premier products Ltd. Coromandel paints & chemicals Ltd. Anupam enterprises Grand polycoats Bombay paints Ltd. Vanaprabha Esters & Glycer , Mumbai Sunil paints and Varnishes Pvt. Ltd. Courtaulds coatings & Sealants India(Pvt.) Ltd. Mark-Chem Incorporated, Mumbai (for phosphating chemicals only) VCM Polyurethane Paints (for polyurethane paints only)

FOREIGN VENDORS FOR OVERSEAS PRODUCTS 1. 2. 3. 4. 5. 6.

Sigma coatings, Singapore Ameron, USA. Kansai paint, Japan Hempel paints, USA. Valspar Corporation, USA Courtaulds coatings, UK.

Note : This list is subjected to revision based on fresh approval.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 43 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 44 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 45 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 46 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 47 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 48 of 49

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

DOCUMENT NO. S-05-02-014

REV-0 Page 49 of 49

Copyright GAIL – All rights reserved

INSPECTION AND TEST PLAN FOR GASKETS

GAIL (INDIA) LTD NEW DELHI

INSPECTION AND TEST PLAN FOR GASKETS

SPECIFICATION S – 05 – 06 - 001

REV- 0 Page 1 of 4 Copyright GAIL – All rights reserved

SL. NO.

STAGE

COMPONENT

CHARACTER ISTICS

METHOD OF CHECK

QUANTUM OF CHECK

REFERENCE DOC.

ACCEPTANCE NORMS

RECORD

SCOPE OF INSPECTION SUB VENDOR

VENDO R

GAIL

1.0

CAF GASKETS

1.1

Raw Material Inspection

CAF Material

Physical

Visual, Dimensional, TC Verification

100 %

IS 2712 Gr. W/1

IS 2712 Gr. W/1

Manufacturer’s TC

W

R

-

1.2

In process inspection (punching & finishing)

CAF Material

Identification Verification

Visual, Dimensional

As per internal QA Plan

ANSI B 16.21, PO, Material Specification

ANSI B 16.21, PO, Material Specification

Inspection Report

-

W

-

1.3

Final Inspection

Gasket

Identification Verification

Visual, Dimensional

100% by Vendor, at random by GAIL

ANSI B 16.21, PO, Material Specification

ANSI B 16.21, PO, Material Specification

Inspection Report

-

W

R

2.0

SPIRAL WOUND

2.1

Raw Material Inspection (Review of mfr’s certificate and check test)

Metaalic spiral winding material, centering ring, Inner ring

Chemical, Visual, Dimensional

Lab Check Visual

100 % lots

Applicable Material specification

Applicable Material specification

Manufacturer’s TC

-

W&R

-

2.2

Raw Material Inspection (Review of mfr’s certificate and check test)

Non- Metallic filler material

Physical

Visual Dimension TC Verification

100 %

Applicable Material specification

Applicable Material specification

Manufacturer’s TC

-

W&R

-

GAIL (INDIA) LTD NEW DELHI

INSPECTION AND TEST PLAN FOR GASKETS

SPECIFICATION S – 05 – 06 - 001

REV- 0 Page 2 of 4 Copyright GAIL – All rights reserved

SL. NO.

STAGE

COMPONENT

CHARACTER ISTICS

METHOD OF CHECK

QUANTUM OF CHECK

REFERENCE DOC.

ACCEPTANCE NORMS

RECORD

SCOPE OF INSPECTION SUB VENDOR

VENDO R

GAIL

2.3

Raw material inspection

Spiral Wound

Compression & recovery test

Test Jig

Lots of every size / rating

ANSI B 16.20, PO, Material Specification

ANSI B 16.20, PO, Material Specification

Inspection report

-

W

H

2.4

Final Inspection

Gasket

Identification Verification

Visual Dimension, Marking

100 % by vendor, at random by GAIL

ANSI B 16.21, PO, Material Specification

ANSI B 16.21, PO, Material Specification

Inspection report

-

W

R

3.0

RTJ GASKET

3.1

Raw material inspection (Document Review)

Seamless ring gasket material

Properties

Chemical Dimension, visual, Hardness

100 %

ANSI B 16.20, PO, Material Specification

ANSI B 16.20, PO, Material Specification

TC, Inspection report

W

W

R

3.2

Raw material inspection (Check Test)

Ring Gasket Material

Properties

Dimension, visual, Hardness

At random

ANSI B 16.20, PO, Material Specification

ANSI B 16.20, PO, Material Specification

Inspection report

-

W

-

3.3

Final Inspection

Gasket

Identification, Verification

Dimension, visual, Hardness

At random

ANSI B 16.20, PO, Material Specification

ANSI B 16.20, PO, Material Specification

TC, Inspection report

-

W

H

3.4

Final Inspection (Non CS)

Gasket

PMI Check

X-Ray Floorescence/ Emission Spectrometer

Std. Spec for PMI

Std. Spec for PMI

Material Specification

Inspection Report

-

W

H

GAIL (INDIA) LTD NEW DELHI

INSPECTION AND TEST PLAN FOR GASKETS

SPECIFICATION S – 05 – 06 - 001

REV- 0 Page 3 of 4 Copyright GAIL – All rights reserved

4.0

JACKETED GASKET

4.1

Raw material Inspection

Metal Jacketed

Properties

Chemical, Dimension thickness, Visual

As per sampling plan

IS 513

IS 513

TC, Inspection report

-

W

-

4.2

Raw material Inspection

Filler

Properties

Dimension, visual, Hardness

At random

ANSI B 16.20, PO, Material Specification

ANSI B 16.20, PO, Material Specification

Inspection report

-

W

-

4.3

Final Inspection

Gasket

Identification verification

Dimension, visual, Hardness

At Random

ANSI B 16.20, PO, Material Specification

ANSI B 16.20, PO, Material Specification

TC, Inspection report

-

W

H

4.4

Final Inspection (Non CS)

Gasket

PMI Check

X-Ray Floorescence/ Emission Spectrometer

Std. Spec for PMI

Std. Spec for PMI

Material Specification

Inspection Report

-

W

H

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.

GAIL (INDIA) LTD NEW DELHI

INSPECTION AND TEST PLAN FOR GASKETS

SPECIFICATION S – 05 – 06 - 001

REV- 0 Page 4 of 4 Copyright GAIL – All rights reserved

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 1 of 7

CONTENTS

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

DEFINITIONS

4.0

PMI EXAMINATION

5.0

ACCEPTABLE METHODS FOR PMI

6.0

EXTENT OF PMI EXAMINATION

7.0

RECORDING AND DOCUMENTATION

8.0

MARKING

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 2 of 7

1.0

SCOPE This specification applies to the requirements for Positive Material Identification (PMI) to be performed at the vendors’ works on Metallic Alloys Materials procured either directly by the GAIL/Owner/Contractor or indirectly through the sub-vendors.

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: -

Alloy Steel Pipes including Pipes

-

Alloy Steel Flanges & Forgings

-

Alloy Steel Fittings including Clad Fittings

-

Alloy Steel fasteners

-

Alloy Cast & Forged steel valves

-

Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)

-

Longitudinal Pipe & Fittings Welds.

-

Gaskets (for Ring Type Joints)

Following Items shall be excluded from scope of PMI examination: -

Gasket other than for Ring Type Joints

-

Internal Components of Valves

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.

2.0

REFERENCE DOCUMENTS GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 3 of 7

2.1

API Recommended Practice 578 (First Edition, May 1999) – Material Verification Programme for new and Existing Alloy Piping System.

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.

4.0

PMI EXAMINATION

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.

4.2

PMI examination of alloy materials is independent of any certification, markings or colour coding that may exist and is aimed at verifying that the alloy used are as per specified grades.

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.

4.5

PMI examination is subject to surveillance inspection by Owner/ GAIL/ TPI.

5.0

ACCEPTABLE METHODS FOR PMI

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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 4 of 7

5.2

Instrument or methods used for PMI examination shall be able to provide quantitative, recordable, elemental composition results for positive identification of alloying elements present.

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.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 5 of 7

6.0

EXTENT OF PMI EXAMINATION

6.1

Following sampling plan shall be applicable for PMI examination of various alloy items: A. Flanges, Fittings, Valves, RTJ Gaskets

_

B. Pipes

_

100% 100% (for pipes procured from traders)

- 2 random samples drawn from each size/ Heat/ Lot (for pipes procured directly from Mills) C. Fasteners Lot Size

Sample Size

Upto 100

2% (Min2)

101 to 500

1% (Min 3)

501 and above

0.5% (Min5)

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

7.0

RECORDING AND DOCUMENTATION The results of PMI examination shall be recorded in aReport Format as enclosed with this specification.

8.0

MARKING

8.1

All alloy materials tested by PMI shall be identified using either of the following methods by indicating “PMI OK”

8.2

a) Bar Code/ Hologram Sticker b) A low stress stamp marking GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 6 of 7

POSITIVE MATERIAL IDENTIFICATION REPORT

Page

of

BULK MATERIAL Project:

Client

Job No

PMI Report No.

Vendor/ sub- Vendor

Purchase Order No:

Testing Agency

Purchase Requisition No:

PMI Location

Bulk Item Type (as per requisition) Material Specification/ Grade Number of Items in Lot Requisition Item No./ Description

Alloy content, Weight (%)

Remarks Accept/ Reject

Element

Cr

Mo

Ni

V

t

Specified range Actual Observations 1. 2. 3. 4 5 6 7 8 Instrument Type/ ID Last Service date

GAIL (INDIA) LTD NEW DELHI

Inspection Agency

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT VENDOR’S WORKS

Witnessed by

SPECIFICATION S – 14 – 02 – 001

REV-0 Page 7 of 7

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFICED OTHERWISE.

2.

DIFFERENT ROU DIMENSIONS MAY BE ADOPTED BASED ON SITE CONDITIONS, CONSTRUCTION METHOD, PIPELINE SIZE, NO. OF PIPELINES AND PROVISION FOR FUTURE PIPELINES.

3.

THE LOCATION OF PIPELINE IN ROU MAY BE CHANGED TO SUIT SITE CONDITIONS, AFTER OBTAINING WRITTEN APPROVAL FROM COMPANY.

4.

FOR LOCATION OF PIPELINE AMRKET WITH RESPECT TO PIPELINE CENTERLINE, REFER APPLICABLE STANDARDS FOR MARKERS.

GAIL (INDIA) LTD NEW DELHI

TYPICAL RIGHT OF USE FOR PIPE LINES

DOCUMENT NO. S-04-01-001

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

5.

ROU WIDTH (A) AND LOCATION OF PIPELINE IN ROU (B) SHOWN IN THIS STANDARD SHALL BE APPLICABLE FOR NEW CONSTRUCTION OF SINGLE PIPELINE IN NORMAL TERRAIN.FOR RESTRICTIONS, IF ANY IN ROU, REFER PROJECT SPECIFIC REQUIREMENTS OF CONTRACT.

GAIL (INDIA) LTD NEW DELHI

TYPICAL RIGHT OF USE FOR PIPE LINES

DOCUMENT NO. S-04-01-001

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFICED OTHERWISE.

2.

TRENCH DIMENSIONS / COVER REQUIREMENTS SHOWN IN THIS STANDARD ARE MINIMUM REQUIRED DIMENSIONS. ANY INCREASE IN TRENCH WIDTH / COVER SHALL BE SPECIFIED IN THE PROJECT SPECIFIC REQUIREMENTS OF CONTRACT.

3.

MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES HAVING JURISDICTION OVER THE AREA.

4.

EXTRA COVER REQUIREMENTS SHALL BE PROVIDED AT OVER BENDS AND SAG BENDS AS REQUIRED DURING CONSTRUCTION.

5.

FOR MINIMUM COVER REQUIREMENTS AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY AREAS, WATER (CANAL) BODIES ETC., REFER RELEVENT STANDARD.

6.

FOR ALL PIPELINES TO BE CONSTRUCTED UNDER THE JURISDICTION OF GOVT. OF INDIA, THE MINIMUM COVER TO BE ADOPTED SHALL BE 1000 MM, IN ACCORDANCE WITH PETROLEUM AND MINERAL PIPELINES (ACQUSITION OF RIGHT OF USER IN LAND) ACT NO. 50, 1962 AND AMENDMENTS THREON, OF GOVT. OF INDIA.

7.

REFER APPLICABLE STANDARDS AND DRAWINGS FOR OFC.

GAIL (INDIA) LTD NEW DELHI

TYPICAL TRENCH DIMENSIONS FOR PIPE LINES

DOCUMENT NO. S-04-01-002

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. PIPE LINE SYMBOLS

S-04-01-003

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TOPOGRAPHICAL SYMBOLS

S-04-01-004

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. APPROVAL OF CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH.

GAIL (INDIA) LTD NEW DELHI

EXISTING PIPELINE ON SLEEPER CROSSING

DOCUMENT NO. S-04-01-005

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH. 8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS / SPECIFICATIONS.

GAIL (INDIA) LTD NEW DELHI

EXISTING PIPELINE ON SLEEPER CROSSING

DOCUMENT NO. S-04-01-005

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. ROAD / HIGHWAY CROSSING SHALL BE RESTORED TO ORIGINAL CONDITION TO THE ENTIRE SATISFACTION OF COMPANY AND CONCERNED AUTHORITIES HAVING JURISDICTION. 3. REFER API 1102 REQUIREMENTS.

(LATEST

EDITION)

FOR

OTHER

DESIGN

AND

INSTALLATION

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.

GAIL (INDIA) LTD NEW DELHI

PIPE LINE ROAD / HIGHWAY UNCASED CROSSING

DOCUMENT NO. S-04-01-006

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN mm, UNLESS SPECIFIED OTHERWISE. 2. VENT AND DRAIN OFF TO FACE LEFT WHEN LOOKING IN DIRECTION OF FLOW AND SHALL BE PARALLEL TO CROSSING. 3. VENT AND DRAIN OFF PIPE SHALL BE API 5L Gr. B OR IS 1239. 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. 5. VENT PIPES MAY BE USED FOR MOUNTING WARNING SIGNS. 6. FOR CASING PIPE REFER, STANDARD NO. S-04-01-008, SCOPE OF WORK AND SOR.

GAIL (INDIA) LTD NEW DELHI

DETAILS OF CASING VENT AND DRAIN OFF

DOCUMENT NO. S-04-01-007

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 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. 3. AT BOTH ENDS OF CASING PIPE, A DOUBLE SET OF INSULATORS SHALL BE INSTALLED. 4. THE MAXIMUM SPACING BETWEEN INSULAORS AS PER MANUFACTURER’S RECOMMENDATION, BUT IN NO CASE MORE THAN 2500 MM. 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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. CASING PIPE DETAILS

S-04-01-008

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN CROSSING PIPELINES. IN SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. CP DETAILS ARE COVERED SEPARATELY. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.

GAIL (INDIA) LTD NEW DELHI

EXISTING UNDER GROUND PIPE CROSSING (TYPE – I)

DOCUMENT NO. S-04-01009

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS / SPECIFICATIONS. 9. APPROVAL OF THE CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.

GAIL (INDIA) LTD NEW DELHI

EXISTING UNDER GROUND PIPE CROSSING (TYPE – I)

DOCUMENT NO. S-04-01009

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN CROSSING PIPELINES. IN SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. CP DETAILS ARE COVERED SEPARATELY. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.

GAIL (INDIA) LTD NEW DELHI

EXISTING UNDER GROUND PIPE CROSSING (TYPE – II)

DOCUMENT NO. S-04-01-010

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS / SPECIFICATIONS. 9. APPROVAL OF THE CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.

GAIL (INDIA) LTD NEW DELHI

EXISTING UNDER GROUND PIPE CROSSING (TYPE – II)

DOCUMENT NO. S-04-01-010

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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. 4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 5. IN CASE OF ARMOURED AC CABLE, SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN PIPELINE AND CABLE ARMOUR. IN CASE OF UNARMOURED AC CABLE, ARRANGEMENT FOR ELECTROMAGNETIC SHIELDING (BY PROVIDING CASING ON EITHER PIPE OR CABLE) SHALL BE CONSIDERED. CP DETAILS ARE COVERED SEPARATELY. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 7. DIMENSION ‘D’ SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. UNDER GROUND CABLE CROSSING

S-04-01-011

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS / SPECIFICATIONS. 9. APPROVAL OF THE CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. UNDER GROUND CABLE CROSSING

S-04-01-011

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. OVERHEAD POWER LINE CROSSING

S-04-01-012

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTE: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. THIS STANDARD IS APPLICABLE FOR 11 KV AND ABOVE POWER LINES ONLY. 3. SUITABLE MEASURES SHALL BE TAKEN FOR THE PROTECTION OF THE LINE AND SECURITY OF PERSONNEL WHEREVER FOUND NECESSARY. 4. APPROVAL OF CROSSING MAY HAVE TO BE OBTAINED FROM CONCERNED AUTHORITIES. 5. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. OVERHEAD POWER LINE CROSSING

S-04-01-012

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTE: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. FOR ALL THE PIPELINES TO BE CONSTRUCTED UNDER THE JURISDICATION OF GOVT. OF INDIA, THE MINIMUM COVER REQUIREMENT IS 1000 MM IN ACCORDANCE WITH GOVT. OF INDIA PETROLEUM PIPELINES (ACQUISITION OF ROU IN LAND) ACT, NO. 50 (1962) AND NO. 13 (1977). ANY EXTRA REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATION. 3. THE MINIMUM COVER SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES. 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. 6. DIMENSION ‘A’ SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500 WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS NO. OF PIPELINES IN SAME TRENCH. 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.

GAIL (INDIA) LTD NEW DELHI

TYPICAL TRENCH DIMENSIONS FOR TWO OR MORE PIPELINES IN COMMON TRENCH

DOCUMENT NO. S-04-01-013

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

DETAIL - X

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. KM POST

S-04-01-014

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. KM POST

S-04-01-014

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.

2.

SCHEME OF PAINTING AND COLOURING:

3.

4.

A.

UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE): COAL TAR EPOXY (MINIMUM 300 MICRONS THK.).

B.

OVERGROUND STEEL STRUCTURE: AS PER STANDARD S-05-02-014.

C.

FIGURES SHALL BE STENCILED ON BOTH SIDES OF THE POSTS IN BLACK.

D.

COLOUR SCHEME FOR PIPELINE CO. MONOGRAM SHALL BE AS DIRECTED BY COMPANY.

E.

POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND WHITE PAINT.

F.

ALL OTHER ABOVE GROUND STEEL SHALL BE PAINTED YELLOW.

LOCATION: A.

KM POST SHALL BE INSTALLED AT EVERY KILOMETER AS PER REQUIREMENTS OF CONTRACT AND AS DIRECTED BY COMPNAY.

B.

COMPANY NAME PLATE SHALL FACE THE PIPE LINE.

C.

KM POST SHALL BE 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH ABOVE.

MATERIAL FOR MARKERS SHALL BE: 

PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5.

THE FOUNDATION SHALL BE MADE OF CONCRETE M20.

6.

THE HEIGHT OF KM POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. KM POST

S-04-01-014

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

LOCATION PLAN FOR BOUNDARY MARKER

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL ROU BOUNDARY MARKER

S-04-01-015

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.

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.

ALL BOUNDARY MARKERS SHALL BE PRECAST AND INSCRIPTIONS SHALL BE ENGRAVED CENTRALLY IN THE MOULD ON ONE FACE.

4.

LETTERS SHALL BE 60 MM HIGH AND 5 MM DEEP.

5.

INSCRIPTIONS SHALL FACE THE PIPELINE.

6.

CONCRETE FOR BOUNDARY MARKERS SHALL BE M20.

7.

ABOVE GROUND PART OF BOUNDARY MARKERS SHALL BE PAINTED YELLOW WITH MINIMUM THREE COATS OF WATER PROOF CEMENT PAINT AS PER IS-5410. INSCRIPTIONS SHALL BE PAINTED BLACK.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL ROU BOUNDARY MARKER

S-04-01-015

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. AERIAL MARKER

S-04-01-016

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. AERIAL MARKER

S-04-01-016

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.

2.

SCHEME OF PAINTING AND COLOURING:

3.

4.

A.

UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE): COAL TAR EPOXY (MINIMUM 300 MICRONS THK.).

B.

OVERGROUND STEEL STRUCTURE: AS PER STANDARD S-05-02-014.

C.

FIGURES SHALL BE STENCILED ON BOTH SIDES OF THE POSTS IN BLACK.

D.

COLOUR SCHEME FOR PIPELINE CO. MONOGRAM SHALL BE AS DIRECTED BY COMPANY.

E.

POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND WHITE PAINT.

F.

ALL OTHER ABOVE GROUND STEEL SHALL BE PAINTED YELLOW.

LOCATION: A.

AERIAL MARKER SHALL BE INSTALLED AT EVERY 5 KILOMETERS AS PER REQUIREMENTS OF CONTRACT AND AS DIRECTED BY COMPNAY.

B.

COMPANY NAME PLATE SHALL BE FIXED ON BOTH SIDES OF THE POST.

C.

AERIAL MARKER SHALL BE 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH ABOVE.

MATERIAL FOR MARKERS SHALL BE: 

PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5.

THE FOUNDATION SHALL BE MADE OF CONCRETE M20.

6.

THE HEIGHT OF POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. AERIAL MARKER

S-04-01-016

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DIRECTION MARKER

S-04-01-017

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

NOTES: 1.

ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.

2.

SCHEME OF PAINTING AND COLOURING: A.

UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE): COAL TAR EPOXY (MINIMUM 300 MICRONS THK.).

B.

OVERGROUND STEEL STRUCTURE: AS PER STANDARD S-05-02-014.

C.

FIGURES SHALL BE STENCILED ON BOTH SIDES OF THE POSTS IN BLACK.

D.

COLOUR SCHEME FOR PIPELINE CO. MONOGRAM SHALL BE AS DIRECTED BY COMPANY.

E.

POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND WHITE PAINT.

F.

ALL OTHER ABOVE GROUND STEEL SHALL BE PAINTED YELLOW.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DIRECTION MARKER

S-04-01-017

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

3.

4.

LOCATION: A.

DIRECTION MARKER SHALL BE INSTALLED AT LOCATIONS AS PER SPECIFICATIONS AS INDICATED IN APPROVED DRAWINGS AND AS DIRECTED BY COMPNAY.

B.

COMPANY NAME PLATE SHALL FACE THE PIPELINE.

C.

DIRECTION MARKER SHALL BE INSTALLED AT 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH ABOVE.

MATERIAL FOR MARKERS SHALL BE: 

PLATE

-

IS 2062 Gr. A



PIPE

-

IS-1239

5.

DIRECTION MARKER SHALL SHOW THE CHANGE IN DIRECTION OF THE PIPELINE. ALIGNMENT.

6.

THE FOUNDATION SHALL BE MADE OF CONCRETE M20.

7.

THE HEIGHT OF POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DIRECTION MARKER

S-04-01-017

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. PIPELINE WARNING SIGN

S-04-01-018

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. SCHEME OF PAINTING AND COLOURING: A.

UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE): COAL TAR EPOXY (MINIMUM 300 MICRONS THK.).

B.

OVERGROUND STEEL STRUCTURE: AS PER STANDARD S-05-02-014.

C.

AREAS SHOWN AS “■” ARE TO BE PAINTED AND AREAS SHOWN AS “□” ARE TO BE PAINTED YELLOW.

D.

ALL LETTERS SHALL BE PAINTED BLACK EXCEPT “WARNING” WHICH SHALL BE PAINTED RED.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. PIPELINE WARNING SIGN

S-04-01-018

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

E.

COLOUR SCHEME FOR PIPELINE CO. MONOGRAM SHALL BE AS DIRECTED BY COMPANY.

F.

POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND WHITE PAINT.

G.

ALL OTHER ABOVE GROUND STEEL SHALL BE PAINTED YELLOW.

3. LOCATION: A.

THE PIPE LINE WARNING SIGN SHALL BE INSTALLED IN ACCORDANCE WITH CONTRACT REQUIREMENTS AND AS DIRECTED BY COMPANY. IT SHALL BE INSTALLED TO THE LEFT OF THE PIPE CENTER LINE VIEWING IN THE DIRECTION OF FLOW AT 300 MM FROM THE PIPE LINE OD AND THE WARNING SIGN PLATE SHALL FACE THE UTILITY BEING CROSSED.

B.

THE WARNING SIGN PLATE MAY BE MOUNTED ON VENT PIPES OR KM POSTS WHEREVER FEASIBLE.

4. MATERIAL FOR MARKERS SHALL BE: 

PLATE

-

IS 2062 Gr. A



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. 6. THE FOUNDATION SHALL BE MADE OF CONCRETE M20. 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. 8. SIGN PLATE IN REGIONAL LANGUAGE SHALL BE PREPARED BY CONTRACTOR ON SMALLER LINES AND GET APPROVED BY COMPANY.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. PIPELINE WARNING SIGN

S-04-01-018

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

PIPE LINE ROAD / HIGHWAY CASED CROSSING

DOCUMENT NO. S-04-01-020

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. REFER API 1102 REQUIREMENTS.

(LATEST

EDITION)

FOR

OTHER

DESIGN

AND

INSTALLATION

3. FOR CASING PIPE DETAILS, REFER SCOPE OF WORK AND SOR. 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. 7. ALL PIPELINE JOINTS SHALL BE RADIOGRAPHED. 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.

GAIL (INDIA) LTD NEW DELHI

PIPE LINE ROAD / HIGHWAY CASED CROSSING

DOCUMENT NO. S-04-01-020

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN mm, UNLESS SPECIFIED OTHERWISE. 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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL STREAM CROSSING

S-04-01-021

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

4. IN DOUBLE SAG CROSSING, GENERALLY COLD FIELD BENDS SHALL BE USED. USE OF FACTORY MADE R=6D BENDS SHALL BE MINIMIZED. R=6D BENDS SHALL BE USED ONLY WITH PRIOR APPROVAL OF COMPANY. 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. 8. THE LOCATON OF CROSSING SWLL BE IN A LONG STRAIGHT STRDCH OF THE STREAM IF POSSIBLE. 9. EXACT POSITION AND ANGLE OF COLD BENDS SHALL BE DETERMINED IN FIELD. 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: (i)

HISTORICAL RECORDS (TO THE EXTENT AVAILABLE)

(ii)

BANK CONDITION VIS-A-VIS EROSION, ETC.

(iii)

EVIDENCE OF EXTINCTION OF VEGITATION ALONG BANKS.

(iv)

DISCUSSIONS WITH LOCAL PEOPLE.

12. THE NUMBER OF WARNING SIGNS SHALL BE a.

1 (ONE) FOR CROSSINGS LESS THAN 15 M WIDTH AT UP STREAM BANK

b.

2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.

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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL STREAM CROSSING

S-04-01-021

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL SLOPE BREAKER DETAILS

S-04-01-022

REV-0 Page 1 of 3 Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL SLOPE BREAKER DETAILS

S-04-01-022

REV-0 Page 2 of 3 Copyright GAIL – All rights reserved

6. BREAKERS SHALL BE INSTALLED IN STEEP SLOPE AREAS (GENERALLY SLOPE 10% OR MORE) AS SHOWN IN DRAWINGS AND WHEREVER INSTRUCTED BY ENGINEER-IN-CHARGE. 7. TOP LAYER OF TRENCH SHALL BE BACKFILLED WITH SOIL OR CRUSHED ROCK (EXCAVATED MATERIAL). 8. THE REMAINING TRENCH AREA SHALL BE BACKFILLED AS REQUIRED. 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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL SLOPE BREAKER DETAILS

S-04-01-022

REV-0 Page 3 of 3 Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

BANK PROTECTION DETAILS FOR WATER CROSSINGS

DOCUMENT NO. S-04-01-023

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

BANK PROTECTION DETAILS FOR WATER CROSSINGS

DOCUMENT NO. S-04-01-023

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM. 2. MATTRESSES SHALL BE INSTALLED AFTER COMPLETION OF GRADING. 3. IF MORE THAN ONE MATTRESSIS USED, ADJACENT MATTRESSES SHALL BE LACED TOGETHER. 4. DIMENSIONS ‘X’ SHALL BE 2 M OR 10 M AS PER STANDARD SPECIFICATIONS S-04-02-026 AND S-04-02-027. INSTALLATION PROCEDURE: 1. OPEN MESH BUNDLE AND STRETCH OUT BASE PANEL. 2. LACE TOGETHER THE SIDE, END PANELS AND DIAPHRAGM. 3. FILL WITH GRADED STONES OF 75-150 MM 4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS. 5. ANCHOR THE TOP MATTRESS. GAIL (INDIA) LTD NEW DELHI

BANK PROTECTION DETAILS FOR WATER CROSSINGS

DOCUMENT NO. S-04-01-023

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL DETAILS OF RAILWAY CROSSING

S-04-01-024

REV-0 Page 1 of 3 Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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. 4. REFER API RP 1102 FOR OTHER DESIGN AND INSTALLATION REQUIREMENTS. 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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL DETAILS OF RAILWAY CROSSING

S-04-01-024

REV-0 Page 2 of 3 Copyright GAIL – All rights reserved

7. CASING PIPE SHALL BE AS PER SCOPE OF WORK AND SOR. 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. 14. ALL CARRIER PIPE JOINTS SHALL BE RADIOGRAPHED. 15. COATING OF CASING PIPE SHALL BE AS PER REQUIREMENT OF AUTHORITIES. 16. FOR VENT, DRAIN, CASING PIPE, INSULATORS, INSULATOR SPACING, CASING END SEASL ETC. REFER RELEVENT STANDARDS (S-04-01-007 & S-04-01-008)

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TYPICAL DETAILS OF RAILWAY CROSSING

S-04-01-024

REV-0 Page 3 of 3 Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM. 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.

GAIL (INDIA) LTD NEW DELHI

SELECT BACK FILL FOR STATION APPROACH

DOCUMENT NO. S-04-01-026

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

3. MINIMUM PIPE LINE COVER SHALL BE 1000 MM. ANY EXTRA COVER REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATIONS / STANDARDS / DRAWINGS. 4. MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES WHEREVER REQUIRED. 5. FOR MINIMUM COVER REQUIREMENT AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY AREAS ETC. REFER GAIL STANDARDS / DRAWINGS. 6. TRENCH CROSS SECTION SHALL BE VIEWED IN DIRECTION OF FLOW.

GAIL (INDIA) LTD NEW DELHI

SELECT BACK FILL FOR STATION APPROACH

DOCUMENT NO. S-04-01-026

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SLOPE STABILIZATION IN GHAT / HILL AREAS

DOCUMENT NO. S-04-01-027

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 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. 3. MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES WHEREVER REQUIRED. 4. FOR MINIMUM COVER REQUIREMENT AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, WATER BODIES, MARSHY AREAS ETC. REFER GAIL STANDARDS. 5. SUITABLE DRAIN SHALL BE PROVIDED PARALLEL, ALL ALONG THE PIPE LINE TRENCH AND ACROSS AT EVERY 250 M.

GAIL (INDIA) LTD NEW DELHI

SLOPE STABILIZATION IN GHAT / HILL AREAS

DOCUMENT NO. S-04-01-027

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SOIL STABILIZATION IN HILLY AREAS

DOCUMENT NO. S-04-01-028

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SOIL STABILIZATION IN HILLY AREAS

DOCUMENT NO. S-04-01-028

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 2. MATTRESSES SHALL BE INSTALLED AFTER COMPLETION OF GRADING. 3. IF MORE THAN ONE MATTRESSIS USED, ADJACENT MATTRESSES SHALL BE LACED TOGETHER. INSTALLATION PROCEDURE: 1. OPEN MESH BUNDLE AND STRETCH OUT BASE PANEL. 2. LACE TOGETHER THE SIDE, END PANELS AND DIAPHRAGM. 3. FILL WITH GRADED STONES OF 75-150 MM 4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS. 5. ANCHOR THE TOP MATTRESS.

GAIL (INDIA) LTD NEW DELHI

SOIL STABILIZATION IN HILLY AREAS

DOCUMENT NO. S-04-01-028

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. 2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. THE NUMBER OF WARNING SIGNS SHALL BE: a. b.

1 (ONE) FOR CROSSINGS LESS THAN 15 M WIDTH. 2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.

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. 6. CASING PIPE SHALL BE AS PER SCOPE OF WORK AND SOR. 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. 8. PIPELINE SECTION SHALL BE PRE-TESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN LINE TESTING WHEN REQUIRED BY THE CONCERNED AUTHORITIES AND/OR AS DIRECTED BY THE COMPANY REPRESENTATIVE. 9. SEPARATE CASING PIPES SHALL BE INSTALLED FOR OFC AT MINIMUM DISTANCE FROM CASING FOR CARRIER PIPE, IF SPECIFIED. GAIL (INDIA) LTD NEW DELHI

TYPICAL LINED CANAL CASED CROSSING DETAIL

DOCUMENT NO. S-04-01-029

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

10. JACKING/BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING. 11. ALL PIPELINE JOINTS SHALL BE RADIOGRAPHED. 12. FOR DRAIN, VENT, CASING PIPE, INSULATOR, INSULATOR SPACING, END SEALS ETC. REFER RELEVENT STANDARD / SPECIFICATIONS.

GAIL (INDIA) LTD NEW DELHI

TYPICAL LINED CANAL CASED CROSSING DETAIL

DOCUMENT NO. S-04-01-029

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. 2. CANAL CROSSING SHALL BE RESTORED TO ORIGINAL CONDITION TO THE SATISFACTION OF COMPANY AND CONCERNED AUTHORITIES HAVING JURISDICTION.

ENTIRE

3. THE NUMBER OF WARNING SIGNS SHALL BE: a. b.

1 (ONE) FOR CROSSING LESS THAN 15 M WIDTH. 2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.

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. 6. IN CASE PIPELINE COATING IS LIABLE TO DAMAGE WHILE BORING / JACKING, A PROTECTIVE COATING OVER CORROSION COATING OF SUITABLE MATERIAL (APPROVED BY COMPANY) SHALL BE PROVIDED AS DIRECTED BY ENGINEER-IN-CHARGE. 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.

GAIL (INDIA) LTD NEW DELHI

TYPICAL LINED CANAL UNCASED CROSSING DETAIL

DOCUMENT NO. S-04-01-030

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. 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. 4. REFER APPLICABLE STANDARD/ DRAWINGS FOR DETAILS OF OFC. 5. FOR TRENCH DETAILS REFER STD. NO. S-04-01-002. 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. 7. RESTORATION OF ROU SHALL BE CARRIED OUT AS PER THE INSTRUCTIONS OF ENGINEER-INCHARGE.

GAIL (INDIA) LTD NEW DELHI

TYPICAL CROSS SECTION FOR ROU PREPARATION IN HILL AREAS

DOCUMENT NO. S-04-01-031

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

JACK SCREW FOR SPECTACLE BLIND FIG 8 (150#, 300#, 600# RF)

STANDARD S-05-01-001

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

JACK SCREW FOR SPACERS AND BLINDS (150#, 300#, 600# RF)

STANDARD S-05-01-002

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

VENTS AND DRAINS (ON LINES 1-1/2” AND BELOW)

STANDARD S-05-01-003

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

VENTS AND DRAINS (ON LINES 2” AND ABOVE)

STANDARD S-05-01-004

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELLS INSTALLATION 1-1/2” DIA TAPS

STANDARD S-05-01-005

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELLS INSTALLATION 1-1/2” DIA TAPS

STANDARD S-05-01-005

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

PRESSURE TAPPING (PA, PG, PC, PT, PIC ETC)

STANDARD S-05-01-006

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DIMESIONS FOR HANDLE PROJECTION FOR SPACERS AND BLINDS: ½” – 24” NB (150#, 300#, 600# FF)

SPECIFICATION S-05-01-007

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

T – STRAINER TYPE-1 2” – 4” (150# RF, 300# RF AND RTJ, 600# RF AND RTJ)

SPECIFICATION S-05-01-008

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

T – STRAINER TYPE-1 6” – 24” (150# RF, 300# RF AND RTJ, 600# RF AND RTJ)

SPECIFICATION S-05-01-009

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. ORIENTATION OF ORIFICE TAPS

S-05-01-010

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. STUB-IN STANDARD

S-05-01-011

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. STUB-IN STANDARD

S-05-01-011

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING OF PIPEWITH DIFFERENT THICKNESS

DOCUMENT NO. S-05-01-012

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. FILLET WELD DETAILS

S-05-01-013

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

WELDING DETAILS FOR BRANCH CONNECTION

DOCUMENT NO. S-05-01-014

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

METHOD OF CUTTING AND DIMENSIONS OF FIELD MANUFACTURED CONCENTRIC REDUCERS

DOCUMENT NO. S-05-01-015

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 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. C. ± 1.5 MM MAX. ROTATION FROM THE INDICATED POSITION, MEASURED AS SHOWN. D. ± 1 MM MAX. OUT OF ALIGNMENT FROM THE INDICATED POSITION MEASURED ACROSS ANY DIAMETER AS SHOWN. GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TOLERENCE FOR FABRICATION

S-05-01-016

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

E. FLATTENING, MESAURED AS DIFFERENCE BETWEEN MAX. AND MIN. OD AT ANY CROSS SECTION. -3% MAX. FOR PIPE WITH EXTERNAL PRESSURE. 8% MAX. FOR PIPE WITH INTERNAL PRESSURE.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. TOLERENCE FOR FABRICATION

S-05-01-016

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

MATERIAL: SHOE INSULATION THK. UP TO 75 76 TO 125 126 TO 175 GUIDE PLATE: IS 2062

GAIL (INDIA) LTD NEW DELHI

H 100 150 200

SHOE SIZE A B C

CUT FROM ISMB 200 300 400

PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 2” THRU 8” TYPE - S1 (FOR TEMP.UPTO 3430C)

X 44 46 49

DOCUMENT NO. S-05-01-017

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

MAXIMUM ALLOWABLE LOAD ON FILLET WELD OF RESTRAINT (KG/CM) TEMPERATURE IN DEG C WELD SIZE (MM) 200 250 300 6 340 250 220 8 450 340 300 10 560 420 370

350 200 270 330

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. 4. GUIDE PLATES SHALL BE WELDED ON BOTH SIDES. 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.

GAIL (INDIA) LTD NEW DELHI

PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 2” THRU 8” TYPE - S1 (FOR TEMP.UPTO 3430C)

DOCUMENT NO. S-05-01-017

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

Note: 1. LOADS ON FILLET WELD OF GUIDES / CROSS-GUIDE / ANCHOR SHALL BE LIMITED TO THE VALUES TABULATED AGAINST VARIOUS TEMPERATURES FOR THE RESPECTICE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 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.

GAIL (INDIA) LTD NEW DELHI

PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 10” THRU 30” TYPE – S2 (FOR TEMP.UPTO 3430C)

DOCUMENT NO. S-05-01-018

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

3. FOR FIG. 3 AND 4, IF THE REQUIRED GUIDE-GAP IS MORE THAN 3MM, DIMENSIONS OF THE GUIDE PLATE SHALL BE SUITABLE MODIFIED. 4. GUIDEPLATES SHALL BE WELDED ON BOTH SIDES. 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.

GAIL (INDIA) LTD NEW DELHI

PIPE SHOE FOR HOT INSULATED CS PIPE , SIZE 10” THRU 30” TYPE – S2 (FOR TEMP.UPTO 3430C)

DOCUMENT NO. S-05-01-018

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

MAXIMUM ALLOWABLE LOAD ON FILLET WELD OF RESTRAINT (KG/CM) TEMPERATURE IN DEG C WELD SIZE (MM) 200 250 300 6 340 250 220 8 450 340 300 10 560 420 370

GAIL (INDIA) LTD NEW DELHI

PIPE SADDLE FOR CS BARE PIPE, SIZE 14” THRU 48”, TYPE – S6A (FOR TEMP. UP TO 3430C)

350 200 270 330

DOCUMENT NO. S-05-01-019

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

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. 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. 4. GUIDE PLATES SHALL BE OF IS-2062. THEY SHALL BE WELDED ON BOTH SIDES. 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.

GAIL (INDIA) LTD NEW DELHI

PIPE SADDLE FOR CS BARE PIPE, SIZE 14” THRU 48”, TYPE – S6A (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-019

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

PIPE SHOE FOR HOT INSULATION EXCEEDING 175MM / SLOPE LINE PIPE, SIZE 2” THRU 6” TYPE – S9A / S9B / S9C

DOCUMENT NO. S-05-01-020

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

Note: 1. LOADS ON FILLET WELD OF GUIDES / CROSS-GUIDE / ANCHOR SHALL BE LIMITED TO THE VALUES TABULATED AGAINST VARIOUS TEMPERATURES FOR THE RESPECTICE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES. 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. 4. GUIDEPLATES SHALL BE WELDED ON BOTH SIDES. 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.

GAIL (INDIA) LTD NEW DELHI

PIPE SHOE FOR HOT INSULATION EXCEEDING 175MM / SLOPE LINE PIPE, SIZE 2” THRU 6” TYPE – S9A / S9B / S9C

DOCUMENT NO. S-05-01-020

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36” TYPE – L1 AND L1A

DOCUMENT NO. S-05-01-021

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTE: 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. B.

FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CS I.E. M=0. FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING: 

FOR h≤ 500 MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE I.E. M = h. FOR h > 500 MM, SUPPORT PIPE SHALL BE COMPOSITE WITH ‘M = INSULATION THICKNESS + 25 MM ‘ OR 100 MM WHICHEVER IS GREATER.



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: A.

FOR CLASS #150 & #300 PIPING: CS & AS LINES SS LINES -

B.

10” AND ABOVE 2” AND ABOVE

FOR CLASS #600 AND HIGHER CS, AS AND SS -

10” AND ABOVE

5. DIMENSION ‘C’ IS TO BE MODIFIED IF OTHER THAN R=1.5D ELBOWS ARE USED. 6. IN CASE CLACULATED h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36” TYPE – L1 AND L1A

DOCUMENT NO. S-05-01-021

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTE: 1.

FOR THE APPLICABLE SIZE NOS., DIMENSIONS TABLE AND NOTES, REFER GAIL STANDARD S-05-01-021.

2.

REFER VIEW A-A OF GAIL STANDARD S-05-01-021.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT FIXED FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36” TYPE – L3 AND L3A

DOCUMENT NO. S-05-01-022

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING FOR BARE PIPE SIZE 3/4” THRU 36”, TYPE – L5 AND L5A (FOR TEMP. UP TO 4000C)

DOCUMENT NO. S-05-01-023

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTE: 1.

WELDED ATTACHEMENT (6MM THICK) REQUIRED ONLY IN CASE OF STAINLESSSTEEL / ALLOY STEEL LINE PIPE. MATERIAL OF WELDED ATTACHMENT SHALL BE SAME AS THAT OF LINE PIPE.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L6

DOCUMENT NO. S-05-01-024

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

2.

PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR EQUIVALENT PLATE AND SHALL BE AS PER VIEW A-A OF GAIL STANDARD S-05-01-021.

3.

FOR LINE TEMPERATURES UP TO 4000C, CONNECTING PLATE SHALL BE CARBON STEEL. FOR HIGHER TEMPERATURES IT SHALL BE SAME AS THAT OF LINE PIPE.

4.

IN CASE CALCULATED H/h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L6

DOCUMENT NO. S-05-01-024

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

(PLEASE REFER NOTES MENTIONED IN NEXT PAGE)

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT FIXED / RESTRAINED FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L7 AND L7A

DOCUMENT NO. S-05-01-025

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

NOTE: 1.

WELDED ATTACHEMENT (6MM THICK) REQUIRED ONLY IN CASE OF STAINLESSSTEEL / ALLOY STEEL LINE PIPE. MATERIAL OF WELDED ATTACHMENT SHALL BE SAME AS THAT OF LINE PIPE.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT FIXED / RESTRAINED FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L7 AND L7A

DOCUMENT NO. S-05-01-025

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

2.

PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR EQUIVALENT PLATE AND SHALL BE AS PER VIEW A-A OF GAIL STANDARD S-05-01-021.

3.

FOR LINE TEMPERATURES UP TO 4000C, CONNECTING PLATE SHALL BE CARBON STEEL. FOR HIGHER TEMPERATURES IT SHALL BE SAME AS THAT OF LINE PIPE.

4.

IN CASE CALCULATED H/h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT FIXED / RESTRAINED FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L7 AND L7A

DOCUMENT NO. S-05-01-025

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

NOTE: 1.

FOR THE APPLICABLE SIZE NOS., DIMENSION TABLE, NOTES AND VIEW A-A, REFER GAIL STANDARD S-05-01-021.

GAIL (INDIA) LTD NEW DELHI

RESTRAINED LOW SUPPORT FOR BARE AND INSULATED PIPE, SIZE 2” THRU 36”, TYPE – L8 AND L8A

DOCUMENT NO. S-05-01-026

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

INSTALLATION PROCEDURE: 1.

PLACE SUPPORT UNDER PIPE BEFORE CONNECTING PIPE TO EQUIPMENT. TURN ADJUSTING NUT UNTIL PIPE FLANGE IS ALIGNED WITH EQUIPMENT OR VALVE FLANGE.

NOTES: 1.

ALL PLATES SHALL BE CARBON STEEL WHERE DESIGN TEMPERATURE ≥ 4000C WITH h≤ 200mm. BASE PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL.

2.

REFER NOTES 2, 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.

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.

4.

HEX HEAD OF SLIDING BOLT TO BE GROUND SMOOTH.

GAIL (INDIA) LTD NEW DELHI

ADJUSTABLE LOW SUPPORT SLIDING FOR BARE AND INSULATED PIPE, SIZE 2” THRU 6”, TYPE – L10 AND L10A

DOCUMENT NO. S-05-01-027

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES: 1.

FOR DETAILS OF U-BOLT TYPE C-4, REFER GAIL STANDARD S-05-01-021.

2.

U-BOLT MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING AND FIXED FOR BARE AND INSULATED PIPE, SIZE 3/4” THRU 1-1/2”, TYPE – L15

DOCUMENT NO. S-05-01-028

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

3.

FOR DETAIL-M, FOR CARBON STEEL (CS) PIPE, USE CS ANGLE. IN CASE OF ALLOY STEEL / STAINLESS STEEL USE 6MM THK. PLATE MATERIAL EQUIVALENT TO THAT OF LINE PIPE.

4.

IN CASE CALCULATED H EXCEEDS THE MAXIMUM VALUE, THE PEDESTAL SHALL BE RAISED ACCORDINGLY.

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT SLIDING AND FIXED FOR BARE AND INSULATED PIPE, SIZE 3/4” THRU 1-1/2”, TYPE – L15

DOCUMENT NO. S-05-01-028

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

LOW SUPPORT STANCHION FOR BARE AND INSULATED CS / AS / SS PIPE, TYPE – L16

DOCUMENT NO. S-05-01-029

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

INSTALLATION PROCEDURE: 1.

PLACE SUPPORT UNDER PIPE BEFORE CONNECTING PIPE TO EQUIPMENT. TURN ADJUSTING NUT UNTIL PIPE FLANGE IS ALIGNED WITH EQUIPMENT OR VALVE FLANGE.

NOTES: 1.

ALL PLATES SHALL BE CARBON STEEL.

2.

REFER NOTES 2, 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.

GAIL (INDIA) LTD NEW DELHI

ADJUSTABLE LOW SUPPORT WITH FOUR BOLTS FOR PIPE SIZES 8” THRU 24”, TYPE – L17 AND L17A

DOCUMENT NO. S-05-01-030

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

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.

GAIL (INDIA) LTD NEW DELHI

ADJUSTABLE LOW SUPPORT WITH FOUR BOLTS FOR PIPE SIZES 8” THRU 24”, TYPE – L17 AND L17A

DOCUMENT NO. S-05-01-030

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

INSTALLATION PROCEDURE: 1.

PLACE SUPPORT UNDER PIPE BEFORE CONNECTING PIPE TO EQUIPMENT. TURN ADJUSTING NUT UNTIL PIPE FLANGE IS ALIGNED WITH EQUIPMENT OR VALVE FLANGE.

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.

REFER NOTES 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.

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.

GAIL (INDIA) LTD NEW DELHI

ADJUSTABLE LOW SUPPORT FOR BARE AND INSULATED PIPE, SIZES 2” THRU 24”, TYPE – L18 AND L18A

DOCUMENT NO. S-05-01-031

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

INSTALLATION PROCEDURE: 1.

PLACE SUPPORT UNDER PIPE BEFORE CONNECTING PIPE TO EQUIPMENT. TURN ADJUSTING NUT UNTIL PIPE FLANGE IS ALIGNED WITH EQUIPMENT OR VALVE FLANGE.

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.

REFER NOTES 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.

GAIL (INDIA) LTD NEW DELHI

ADJUSTABLE LOW SUPPORT WITH GUIDE AND CROSS GUIDE FOR BARE AND INSULATED PIPE, SIZES 2” THRU 24”, TYPE – L19 AND L19A

DOCUMENT NO.

REV-0 Page 1 of 2

S-05-01-032 Copyright GAIL – All rights reserved

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.

GAIL (INDIA) LTD NEW DELHI

ADJUSTABLE LOW SUPPORT WITH GUIDE AND CROSS GUIDE FOR BARE AND INSULATED PIPE, SIZES 2” THRU 24”, TYPE – L19 AND L19A

DOCUMENT NO.

REV-0 Page 2 of 2

S-05-01-032 Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

PIPE CLAMP FOR BARE CS / AS / SS PIPE, SIZE ½” THRU 24”, TYPE – C1

DOCUMENT NO. S-05-01-033

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

U-BOLT FOR BARE CS PIPE, SIZE ½” THRU 24”, TYPE – C4 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-034

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

NOTES:

α TO BE GIVEN IN CASE SUPPORT IS WELDED TO VERTICAL

1.

REFERENCE LEVEL AND SUPPORT.

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.

GAIL (INDIA) LTD NEW DELHI

DUMMY PIPE SUPPORT FOR BARE PIPE, SIZE 2” THRU 24”, TYPE-B39

DOCUMENT NO. S-05-01-035

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved



3.

FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING: -

FOR (L-0.50) ≤ 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE I.E. M= (L-0.50).

-

FOR (L-0.50) > 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M = 25MM + INSULATION THICKNESS OR 100MM WHICHEVER IS GREATER.

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.

GAIL (INDIA) LTD NEW DELHI

DUMMY PIPE SUPPORT FOR BARE PIPE, SIZE 2” THRU 24”, TYPE-B39

DOCUMENT NO. S-05-01-035

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES:

α TO BE GIVEN IN CASE SUPPORT IS WELDED TO VERTICAL

1.

REFERENCE LEVEL AND SUPPORT.

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. DOCUMENT NO. REV-0 DUMMY PIPE SUPPORT FOR GAIL (INDIA) LTD INSULATED PIPE, SIZE 2” THRU 24”, Page 1 of 2 S-05-01-036 NEW DELHI TYPE- B40 Copyright GAIL – All rights reserved



3.

FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING: -

FOR (L-0.50) ≤ 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE I.E. M= (L-0.50).

-

FOR (L-0.50) > 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M = 25MM + INSULATION THICKNESS OR 100MM WHICHEVER IS GREATER.

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.

GAIL (INDIA) LTD NEW DELHI

DUMMY PIPE SUPPORT FOR INSULATED PIPE, SIZE 2” THRU 24”, TYPE- B40

DOCUMENT NO. S-05-01-036

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. PIPE SUPPORT BRACKETS, TYPE- B42

S-05-01-037

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

GUIDE SUPPORT FOR BARE PIPE, SIZE ½” THRU 24”, TYPE- G1

DOCUMENT NO. S-05-01-038

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

GUIDE SUPPORT FOR BARE PIPE, SIZE ½” THRU 24”, TYPE- G2 AND G2A (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-039

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTES: 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.

2.

GUIDE PLATES / ANGLES SHALL BE WELDED ON BOTH SIDES.

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.

GAIL (INDIA) LTD NEW DELHI

GUIDE SUPPORT FOR BARE PIPE, SIZE ½” THRU 24”, TYPE- G2 AND G2A (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-039

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

NOTES: 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.

GAIL (INDIA) LTD NEW DELHI

CROSS GUIDE FOR BARE PIPE, SIZE 2” THRU 24”, TYPE- G3 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-040

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

2.

FOR AS AND SS LINES, 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.

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.

GAIL (INDIA) LTD NEW DELHI

CROSS GUIDE FOR BARE PIPE, SIZE 2” THRU 24”, TYPE- G3 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-040

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

CROSS GUIDE FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G4 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-041

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTE: 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. 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.

GAIL (INDIA) LTD NEW DELHI

CROSS GUIDE FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G4 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-041

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

ANCHOR FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G5 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-042

REV-0 Page 1 of 2

Copyright GAIL – All rights reserved

NOTES: 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.

GAIL (INDIA) LTD NEW DELHI

ANCHOR FOR BARE PIPE ON SLEEPER / RCC BEAM, SIZE 2” THRU 24”, TYPE- G5 (FOR TEMP. UP TO 3430C)

DOCUMENT NO. S-05-01-042

REV-0 Page 2 of 2

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

SUPPORTING ARRANGEMENT FOR ANGLE AND RELIEF VALVES, TYPE – SP2

DOCUMENT NO. S-05-01-043

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

GAIL (INDIA) LTD NEW DELHI

TYPICAL ANTI VIBRATION SUPPORT FOR CONTROL VALVE MANIFOLD, TYPE – SP3

DOCUMENT NO. S-05-01-044

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 - 007 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

-------------

AS

ANSI Rating: Piping class: VALVE BORE: Face finish flanges: Temperature, 0c: Installation: Valve Operating time, Sec

of

600# D1A FULL / REDUCED BORE NOT APPLICABLE

-28 TO 65 BURIED 60

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm VALVE OPERATOR REQUIREMENT Type of Operator GAS POWERED ACTUATOR Operator Spec. No.: S – 04 – 02 - 012 Operator Data Sheet:

STEM EXTENSION REQUIREMENT Stem Extension REQUIRED Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB (REFER NOTE-1) Ball (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Body Seat Rings (AISI 4140 + 0.003” ENP) / AISI 410 Seat Seal (Secondary) VITON Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / VITON Stud, Bolts ASTM A 193 Gr. B7/ Gr. B7M Nuts ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7

2.5 (APPROX.)

MATERIAL OFFERED

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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DATA SHEET FOR BALL VALVES

0001-01-04-04-BV-001

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 - 007 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

-------------

AS

ANSI Rating: Piping class: VALVE BORE: Face finish flanges: Temperature, 0c: Installation: Valve Operating time, Sec

of

600# D1A FULL / REDUCED BORE NOT APPLICABLE

-28 TO 65 ABOVE GROUND 60

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm VALVE OPERATOR REQUIREMENT Type of Operator GAS POWERED ACTUATOR Operator Spec. No.: S – 04 – 02 - 012 Operator Data Sheet:

STEM EXTENSION REQUIREMENT Stem Extension NOT APPLICABLE Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB (REFER NOTE-1) Ball (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Body Seat Rings (AISI 4140 + 0.003” ENP) / AISI 410 Seat Seal (Secondary) VITON Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / VITON Stud, Bolts ASTM A 193 Gr. B7/ Gr. B7M Nuts ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7

-----

MATERIAL OFFERED

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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DATA SHEET FOR BALL VALVES

0001-01-04-04-BV-002

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 - 007 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor:

0.5

-------------

AS

ANSI Rating: Piping class: VALVE BORE: Face finish flanges: Temperature, 0c: Installation: Valve Operating time, Sec

of

600# D1A FULL / REDUCED BORE NOT APPLICABLE

-28 TO 65 BURIED GROUND 60

/

ABOVE

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm VALVE OPERATOR REQUIREMENT Type of Operator GEAR OPERATED Operator Spec. No.: Operator Data Sheet:

STEM EXTENSION REQUIREMENT Stem Extension NOT APPLICABLE ----Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB (REFER NOTE-1) Ball (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Body Seat Rings (AISI 4140 + 0.003” ENP) / AISI 410 Seat Seal (Secondary) VITON Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / VITON Stud, Bolts ASTM A 193 Gr. B7/ Gr. B7M Nuts ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7

MATERIAL OFFERED

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.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DATA SHEET FOR BALL VALVE

0001-01-04-04-BV-003

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 – 008 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

------------ANSI Rating: Piping class: AS

Face finish flanges: Temperature, 0c: Installation:

600# D1A of

NOT APPLICABLE

-28 TO 65 ABOVE GROUND

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm 7.9 Grade API 5L Gr. X60 VALVE OPERATOR REQUIREMENT Type of Operator Manual (Note-1) Operator Spec. No.: Operator Data Sheet: -

STEM EXTENSION REQUIREMENT Stem Extension Not Required Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Plug (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Cover ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / GRAPHITE / VITON Stud, Bolts ASTM A 193 Gr. B7 Nuts ASTM A 194 Gr. 2H

MATERIAL OFFERED

Note: Requirement of Manual operator (Wrench / Hand Wheel / Gear operator) shall be as per Specification - S–04–02–008. 2. Separate wrench shall be provided with each wrench operated valve. 3. Data Sheets shall be read in conjunction with Valve specifications - S–04–02–008. 1.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DATA SHEET FOR PLUG VALVES

0001-01-04-04-PV-001

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

Valve Manufacturer Actuator Manufacturer Valve Tag No. Purchaser’s spec.: S – 04 – 02 – 008 Design standard: API 6D SIZE, mm (IN) NB: Ends: BOTH ENDS BW PER ASME B 16.25 VALVE DESIGN CONDITIONS: Corrosion Allowance: 1.5 mm Service R-LNG Design factor: 0.5

------------ANSI Rating: Piping class: AS

Face finish flanges: Temperature, 0c: Installation:

600# D1A of

NOT APPLICABLE

-28 TO 65 BURIED

CONNECTING PIPE DETAILS: Diameter (NB), mm Wall Thickness, mm 7.9 Grade API 5L Gr. X60 VALVE OPERATOR REQUIREMENT Type of Operator Manual (Note-1) Operator Spec. No.: Operator Data Sheet: -

STEM EXTENSION REQUIREMENT Stem Extension Required 2.5 M (Approx.) Length of Stem extension, m

VALVE MATERIAL SPECIFICATION: PART DESCRIPTION SPECIFIED MATERIAL Body ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Plug (ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB) + 0.003” ENP Cover ASTM A 216 Gr. WCB/ ASTM A 234 Gr. WPB Stem (AISI 4140 + 0.003” ENP) / AISI 410 Stem seal PTFE / GRAPHITE / VITON Stud, Bolts ASTM A 193 Gr. B7 Nuts ASTM A 194 Gr. 2H

MATERIAL OFFERED

Note: Requirement of Manual operator (Wrench / Hand Wheel / Gear operator) shall be as per Specification - S–04–02–008. 2. Separate wrench shall be provided with each wrench operated valve. 3. Data Sheets shall be read in conjunction with Valve specifications - S–04–02–008. 1.

GAIL (INDIA) LTD NEW DELHI

DOCUMENT NO. DATA SHEET FOR PLUG VALVES

0001-01-04-04-PV-002

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

DATA SHEETS GATE VALVE BELOW 2” SPUR LINES OF CHAINSA - JHAJJAR

DATA SHEET GATE VALVE BELOW 2”

GAIL (INDIA) LTD NEW DELHI

DATA SHEET 0001-01-05-04-GV-001

REV-0 Page 1 of 3

Copyright GAIL – All rights reserved

Client

:

Gail (India) Ltd

Client

:

Gail (India)Ltd

Project

:

Std. Specification

Location :

New Delhi

Tag No:

GATE VALVE SPECIFICATION TAG NO. : RATING : SIZE RANGE : 0.25" TO 1.5"

STANDARD : API-602 ENDS : SW 3000 TO B-16.11

DESCRIPTION

CONSTRUCTION

BODY

FORGED

ASTM A 105

BONNET

BOLTED

ASTM A 105

STEM

RISING

13% CR.STEEL (NO CASTING)

WEDGE DISC

SOLID

STELLITED

BODY SEAT RING

RENEWABLE

STELLITED

STEM PACKING

RENEWABLE WITH VALVE OPEN ON STREAM

GRAPHITED ASBESTOS WITH SACRIFICIAL CORR. INHIB.& INCONEL WIRE REINFORCEMENT

HAND WHEEL

NON RISING

MALLEABLE IRON/CAST ST/FAB.ST/DUCT. IRON

MATERIAL

BONNET BOLTS

ASTM A193 GR B7

BONNET NUTS

ASTM A194 GR 2H

BONNET GASKET

SP WND SS316 - CA F1LLER

SPECIAL SERVICE CONDITIONS

MAX TEMP. 427 DEG. C. INTEGRAL

OTHERS

O.S & Y.

HYDROSTATIC TEST PRESSURE

BODY : 2975 PSIG.

TEST PRESSURE WITH AIR

80 PSIG

1

of

1

MANUF'S OFFER

PIPING CLASS : A10A, A11A, A13A, A1A, A20A, A32A, A33A, A3A, A6A, A9A, B13A, B1A, B32A, B6A, B9A, D1A

BACK SEAT & SHOULDER

Sheet No. STANDARD: MFGRS CAT/FIG: RATING: ENDS:

CONSTRUCTION

MATERIAL

SEAT : 2175 PSIG

NOTES 1 2 3 4 5

THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES. 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". NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED. TESTING SHALL BE AS PER API 598

DATA SHEET GATE VALVE BELOW 2”

GAIL (INDIA) LTD NEW DELHI

DATA SHEET 0001-01-05-04-GV-001

REV-0 Page 2 of 3

Copyright GAIL – All rights reserved

Project

:

Location :

Std. Specification New Delhi

Tag No:

GATE VALVE SPECIFICATION TAG NO. RATING : 800 SIZE RANGE : 0.5" TO 1.5" DESCRIPTION

CONSTRUCTION

BODY

FORGED

ASTM A 350 GR.LF2

BONNET

BOLTED

ASTM A 350 GR.LF2

STEM

RISING

SS 304/SS316 (NO CASTING)

WEDGE DISC

SOLID

STELLITED

BODY SEAT RING

RENEWABLE

STELLITED

STEM PACKING

RENEWABLE WITH VALVE OPEN ON STREAM

ASBESTOS IMPREGNATED WITH PTFE

HAND WHEEL

NON RISING

MALLEABLE IRON/CAST ST/FAB.ST/DUCT. IRON

MATERIAL

BONNET BOLTS

ASTM A320 GR L7

BONNET NUTS

ASTM A194 GR 4/GR 7

BONNET GASKET

SP WND SS316 - CA FILLER LT

BACK SEAT & SHOULDER

INTEGRAL

OTHERS

O.S & Y.

HYDROSTATIC TEST PRESSURE

BODY : 2975 PSIG.

TEST PRESSURE WITH AIR

80 PSIG

1

of

1

MANUF'S OFFER

PIPING CLASS : A4A, B4A, D4A STANDARD : API-602 ENDS : SW 3000 TO B-16.11

SPECIAL SERVICE CONDITIONS

Sheet No.

STANDARD: MFGRS CAT/FIG: RATING: ENDS: CONSTRUCTION

MATERIAL

UPTO -45 DEG. C.

SEAT : 2175 PSIG

NOTES 1 2 3 4 5 6

THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES. 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". NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED. TESTING SHALL BE AS PER API 598 & BS-6364. VALVES SHALL BE PROVIDED WITH EXTENDED BONNET AS PER BS 6364 (NON COLD BOX APPLICATION). VALVES TO COMPLY WITH DESIGN REQUIREMENTS OF BS-6364 ALSO.

DATA SHEET GATE VALVE BELOW 2”

GAIL (INDIA) LTD NEW DELHI

DATA SHEET 0001-01-05-04-GV-001

REV-0 Page 3 of 3

Copyright GAIL – All rights reserved

ITEM REFERENCE SPECIFICATION

PIPE LINE FLOW TEE (BARRED TEE) SPEC. NO.: S – 04 – 02 - 016

INSTALLATION CONDITIONS: LOCATION SULTANPUR PIG LAUNCHER STATION, NEEMRANA PIG RECEIVER STATION INSTALLATION ABOVE GROUND DESIGN CONDITIONS: BARRED TEE SIZE (NB, INCHES) DESIGN CODE DESIGN FACTOR CORROSION ALLOWANCE DESIGN PRESSURE DESIGN TEMPERATURE IMPACT TEST TEMPERATURE TRANSPORTED GAS SOUR SERVICE POST WELD HEAT TREATMENT OF FIELD WELDS RADIOGRAPHY INSPECTION PAINTING MATERIALS: TEE GUIDE BARS NO. OF BARS TEST RING (1 NO.)

18 X 18 X 18 ASME B 31.8 0.5 NIL 99.93 KG/CM2 (G) (-) 28 TO 650C (-) 280C NATURAL GAS NO NO IF WALL THICKNESS OF TEE IS GREATER THAN 20MM, RI SHALL BE REPLACED WITH UT AS PER CLAUSE 6.0 OF SPECIFICATION NO. S – 04 – 02 - 016

MSS SP-75, Gr. WPHY-70 MANUFACTURER TO SPECIFY 9 18” X 500MM X 9.3 MM

CONNECTING PIPE DETAILS HEADER PIPE DETAILS BRANCH PIPE DETAILS O.D X W.T (mm) SPEC. O.D X W.T (mm) SPEC. 457 X 9.3 API 5L Gr. 70 457 X 9.3 API 5L Gr. 70

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR BARRED TEE SIZE – 18” X 18” X 18”

DOCUMENT NO. 0001-01-04-04-FLT-001

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

ITEM REFERENCE SPECIFICATION

PIPE LINE FLOW TEE (BARRED TEE) SPEC. NO.: S – 04 – 02 - 016

INSTALLATION CONDITIONS: LOCATION DHARUHERA TOP, BHIWADI-CHOPANKI TOP, KHUSHKHERA TOP INSTALLATION UNDER GROUND DESIGN CONDITIONS: BARRED TEE SIZE (NB, INCHES) DESIGN CODE DESIGN FACTOR CORROSION ALLOWANCE DESIGN PRESSURE DESIGN TEMPERATURE IMPACT TEST TEMPERATURE TRANSPORTED GAS SOUR SERVICE POST WELD HEAT TREATMENT OF FIELD WELDS RADIOGRAPHY INSPECTION PAINTING MATERIALS: TEE GUIDE BARS NO. OF BARS TEST RING (1 NO.)

18 X 18 X 12 ASME B 31.8 0.5 NIL 99.93 KG/CM2 (G) (-) 28 TO 650C (-) 280C NATURAL GAS NO NO IF WALL THICKNESS OF TEE IS GREATER THAN 20MM, RI SHALL BE REPLACED WITH UT AS PER CLAUSE 6.0 OF SPECIFICATION NO. S – 04 – 02 - 016

MSS SP-75, Gr. WPHY-70 MANUFACTURER TO SPECIFY 3 12” X 500MM X 7.9 MM

CONNECTING PIPE DETAILS HEADER PIPE DETAILS BRANCH PIPE DETAILS O.D X W.T (mm) SPEC. O.D X W.T (mm) SPEC. 457 X 9.3 API 5L Gr. 70 323.9 X 7.9 API 5L Gr. 60

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR BARRED TEE SIZE – 18” X 18” X 12”

DOCUMENT NO. 0001-01-04-04-FLT-002

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

ITEM REFERENCE SPECIFICATION

PIPE LINE FLOW TEE (BARRED TEE) SPEC. NO.: S – 04 – 02 - 016

INSTALLATION CONDITIONS: LOCATION TOP IN U/S OF SV-1 & SV-3 IN SULTANPURNEEMRANA SPUR LINE INSTALLATION UNDER GROUND DESIGN CONDITIONS: BARRED TEE SIZE (NB, INCHES) DESIGN CODE DESIGN FACTOR CORROSION ALLOWANCE DESIGN PRESSURE DESIGN TEMPERATURE IMPACT TEST TEMPERATURE TRANSPORTED GAS SOUR SERVICE POST WELD HEAT TREATMENT OF FIELD WELDS RADIOGRAPHY INSPECTION PAINTING MATERIALS: TEE GUIDE BARS NO. OF BARS TEST RING (1 NO.)

18 X 18 X 8 ASME B 31.8 0.5 NIL 99.93 KG/CM2 (G) (-) 28 TO 650C (-) 280C NATURAL GAS NO NO IF WALL THICKNESS OF TEE IS GREATER THAN 20MM, RI SHALL BE REPLACED WITH UT AS PER CLAUSE 6.0 OF SPECIFICATION NO. S – 04 – 02 - 016

MSS SP-75, Gr. WPHY-70 MANUFACTURER TO SPECIFY 3 8” X 500MM X 6.4 MM

CONNECTING PIPE DETAILS HEADER PIPE DETAILS BRANCH PIPE DETAILS O.D X W.T (mm) SPEC. O.D X W.T (mm) SPEC. 457 X 9.3 API 5L Gr. 70 219.1 X 6.4 API 5L Gr. 56

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR BARRED TEE SIZE – 18” X 18” X 8”

DOCUMENT NO. 0001-01-04-04-FLT-003

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

PIG SIGNALLER TAG NO.

ON EQUIPMENT DATA SHEET NO.

PIG SIGNALLER MANUFACTURER PURCHASER'S SPECIFICATIONS PIG SINGALLER MODEL QUANTITY

12-PL-01, 13-PR-01 0001-01-04-04-PSG-001 * S – 04 – 02 - 018 * 4

DESIGN CONDITIONS DESIGN PRESSURE (KG/CM²) DESIGN TEMPERATURE (ºC) DESIGN CODE CORROSION ALLOWANCE (MM) ANSI RATING (#) DESIGN FACTOR SERVICE END CONNECTION INSTALLATION ELECTRICAL AREA CLASSIFICATION

99.93 -28 TO 65 ASME B31.8 & OISD 226 1.5 600 0.5 NATURAL GAS BE ABOVE GROUND IEC - ZONE-1, GAS GROUP-IIA & IB, TEMP. CLASS - T3

PIG SIGNALLER MATERIAL SPECIFICATION BODY INTERNALS

ASTM A105 (CHARPY) SS-316

MICRO SWITCH DETAILS RATING ENCLOSURE CABLE CONNECTION

GAIL (INDIA) LTD NEW DELHI

POTENTIAL FREE CONTACT OF RATING 24V DC, 2A, SPDT WEATHER PROOF TO IP55 & FLAME PROOF EXD. ENCLOSURE CERTIFIED FOR AREA CLASSIFICATION 1/2" NPTF

DOCUMENT NO. DATA SHEET FOR PIG SIGNALER

0001-01-04-04-PSG-001

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

DATA SHEET FOR GAS POWERED ACTUATOR Actuator Manufacturer

:

Specification for Gas Powered Actuator

:

____________________ S-04-02-012

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.

:

2.

Service

:

3.

Actuator Shut off Pressure

4.

Actuator Valve Description Item No. 1 2 3 4

Size, NB mm (in) 18” 12” 10” 8”

Corrosion Allowance 5.

:

NATURAL GAS 92 kg/cm2 (g)

Bore Size Full Bore & Reduced Bore

:

ANSI Rating 600# 600# 600# 600#

1.5 mm

Process Condition: Power Gas Gas Temperature Line gas Pressure Molecular Weight Cp/Cv Compressibility Factor

: : : : : :

Natural Gas -29 to 650C 92 KG/CM2 (MAX.) 17.4 – 17.64 1.50 – 1.60/ 1.65 – 1.75 0.84-0.86 / 0.78 – 0.81 / 0.83 – 0.87

6.

Actuator Type

:

As per Specification

7.

Power Gas feed from Connection from Mainline

:

3/4" NPT

8.

Actuator Remote Operation (for open/close)

:

Required

9.

Valve Position Limit Switch

:

Required (SPDT contact for open and SPDT contact for close positions separately)

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR GAS POWERED VALVE ACTUATOR

DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 1 of 4

Copyright GAIL – All rights reserved

10.

Local/ Remote Selector Switch and its Status contact

:

Required (shall be wired up to junction box as per circuit diagram)

11.

Pneumatic Limit Valves and solenoid, pilot valves to shut off gas supply to actuator when valve reaches one of its end positions

:

Required

12.

Self Retaining System for retaining momentary open and close signals in the control circuit

:

Required

13.

Electrical Conduit connection (Cable entry to junction box for Purchaser’s cable)

:

1" NPT

14.

Operating Voltage :

24 V DC ± 15 %

Limit Switches L/R switch (status)

:

2 Amp at 24 V DC

16.

Pad Lock with L/R Switch

:

Required

17.

Enclosure for

a) b) 15.

Solenoid Valves Relays

Contact Rating a) b)

a)

Actuator

:

Certified Weather Proof as per IP55

b)

Electrical Items like Limit Switches, Solenoid valves, Junction Boxes, Relays, Cable Glands

:

Certified Weather Proof as per IP55 and Flame proof certified suitable for IEC Zone-1, Gas group IIA &IIB, Temp. Class T3

18.

Area Classification

:

IEC Zone-I, Gas Group II A & IIB, Temp. Class T3

19.

Material of Construction for all tubing, valves, piping and fittings

:

SS316

20.

Accessories Required

:

Required as per Specification

21.

Manual/Hydraulic Override

:

Required as per Specification

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR GAS POWERED VALVE ACTUATOR

DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 2 of 4

Copyright GAIL – All rights reserved

22.

Maximum time required to open/close the valve

:

As per Data sheets

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.

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR GAS POWERED VALVE ACTUATOR

DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 3 of 4

Copyright GAIL – All rights reserved

TABLE - 1

DATA FROM BALL VALVE VENDOR ITEM NO.

TAG NO. BREAK TORQUE (NM)

RUNNING TORQUE (NM)

MAX. ALLOWABLE STEM TORQUE (NM)

BALL VALVE TORQUE FIGURES WITH A SAFETY FACTOR 1.25

ACTUATOR GENERATED TORQUE AT 10 KG/CM2 (G) REGULATED PRESSURE (NOTE 1)

BREAK TORQUE (NM)

BREAK TORQUE (NM)

RUNNING TORQUE (NM)

MODEL SELECTED

RUNNING TORQUE (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. 2. All torque figures must be in Nm.

GAIL (INDIA) LTD NEW DELHI

DATA SHEET FOR GAS POWERED VALVE ACTUATOR

DOCUMENT NO. 0001-01-04-04-GVA-001

REV-0 Page 4 of 4

Copyright GAIL – All rights reserved

A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER. 1. INSULATING JOINTS MFR. 2. PURCHASER'S SPECIFICATION NO. 3. RATING 4. DESIGN PRESSURE 5. DESIGN TEMPERATURE 6. SERVICE 7. CORROSION ALLOWANCE 8. SIZE NB (INCHES) 9. END CONNECTION 10. DESIGN CODE 11. DESIGN FACTOR 12. 13. 14. 15.

: : : : : : : : : : :

S – 04 – 02 - 019 600# 99.93 KG/CM2 (G) -29 TO 65°C Natural Gas 1.5 MM 18” / 12” / 10” / 8” BUTT-WELD AT BOTH ENDS ASME SECTION-VIII DIV-I 0.4 (FOR CLASS-4 LOCATION) 0.5 (FOR ALL OTHER AREAS) HYDROSTATIC TEST PRESSURE : 138 KG/CM2 (G) CHARPY TEST : REQUIRED AS PER SPEC. HARDNESS TEST : REQUIRED AS PER SPEC. MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR) A) BODY

:

B) PUPS

:

C) INSULATING MATERIAL: 16. CONNECTING PIPE SPECIFICATION : SIZE, NB, MM (INCHES) WALL THICKNESS, MM GRADE 17. SPECIAL REQUIREMENTS

GAIL (INDIA) LTD NEW DELHI

: : : :

ASTM A-694, GRADE AS PER CONNECTING PIPE GRADE API 5L (GR. &THK. TO SUIT CONNECTING PIPE) AS PER MANUFACTURER'S STANDARD 18" / 12” / 10” / 8” AS PER AREA CLASSIFICATION API 5L Gr. X-70 (18”) API 5L Gr. X-60 (12” & 10”) API 5L Gr. X-56 (8”) INSULATION JOINT SHALL BE SUITABLE FOR ABOVE GROUND INSTALLATION

DATA SHEET FOR INSULATING JOINTS

DOCUMENT NO. 0001-01-04-04-IJ-001

REV-0 Page 1 of 1

Copyright GAIL – All rights reserved

VENDOR LIST The materials required to be supplied by the contractor under this contract shall be procured only from GAIL approved vendors. However, current validity and range of approval as per GAIL enlistment letter, workload, stability and solvency need to be verified by the contractor before placement of order. Approved list of vendors for some of the items are mentioned below or elsewhere in the Bidding document. Where the makes of materials are not indicated in the bidding document, contractor shall furnish the details of makes and shall obtain prior approval of Engineer in charge of vendors/sub-vendors before placing orders. 1)

Fasteners -

2)

Fittings Block forged – Carbon Steel -

3)

Eby Fasteners, India Leader Valves Ltd, India M.S. Fittings Mfg. Co Pvt Ltd, India R.N. Gupta & Co. Ltd, India

Fittings from Seamless Pipe – Carbon Steel -

4)

AEP Company, India Boltmaster India Pvt Ltd, India Deepak Fasteners Limited, India Fasteners & Allied Products Pvt Ltd, India Hardwin Fasteners Pvt Ltd, India J.J. Industries, India Multi Fasteners Pvt Ltd, India Nexo Industries, India Pacific Forging & Fasteners Pvt Ltd, India Pioneer Nuts & Bolts Pvt Ltd, India Precision Auto Engineers, India President Engineering Works, India Sandeep Engineering Works, India Syndicate Engineering Industries, India

Eby Industries, India Gujarat Infrapipes Pvt Ltd, India M.S. Fittings Mfg. Co Pvt Ltd, India Teekay Tubes Pvt Ltd

Flanges - Forged Carbon Steel -

CD Engineering Co., India CD Industries (Ghaziabad), India Chaudhry Hammer Works Ltd, India Echjay Industries Pvt Ltd, (Rajkot), India

VENDOR LIST - PIPING

Page 1 of 4

5)

Flow Tee (Barred TEE) -

6)

Jindal Saw Ltd. (Kosi Works), India PSL Limited (Gandhidham – Mfrg), India

Quick Opening End Closure -

10)

IGP Engineers Pvt. Ltd., India Nouva Giungas SRL, Italy Zunt Italiana SRL., Italy

Long Radius Bends -

9)

IGP Engineers Pvt. Ltd., India Madras Industrial Products, India Starflex Sealing India Pvt Ltd, India

Insulating Joints -

8)

Multitex Filtration Engineers Ltd., India Pipeline Engineering, UK Technoforge SPA, Italy

Gaskets Spiral Wound -

7)

Golden Iron & Steel Works, India J.K. Forgings, India JAV Forgings (P) Ltd, India Kunj Forgings Pvt Ltd, India Metal Forgings Pvt Ltd, India Pradeep Metal Limited, India Punjab Steel Works, India (The) R.N. Gupta & Co. Ltd, India R.P. Engineering Pvt Ltd, India Shri Ganesh Forgings Ltd., India Uma Shankar Khandelwal & Co., India

Forain S.R.L. GD Engineering, India Perry Equipment Corporation, India Pipeline Engineering, UK Siirtec Nigi SPA TD Williamson Inc., USA

Scraper Trap, Pig Signaller -

Cardew Ltd., Alexeander Forain S.R.L. GD Engineering, India Multitex Filtration Engineers Ltd., India

VENDOR LIST - PIPING

Page 2 of 4

11)

Pipe – Carbon Steel (Seamless) to ASTM STDS. -

12)

Larsen & Toubro Ltd, India

Ball Valves, Pipe Line (API 6D) -

14)

BHEL (Trichy), India Heavy Metals & Tubes Ltd (Mehsana), India Indian Seamless Metal Tubes Ltd, Ahmednagar, India Indian Seamless Metal Tubes Ltd, Baramati, India Jindal Saw Ltd (Nashik Works), India Mahalaxmi Seamless Ltd, India Maharashtra Seamless Ltd, India Sainest Tubes Pvt Ltd, India Wuxi Erquan Special Steel Tube Co. Ltd.

Pressure Balanced Plug Valve (NFS) -

13)

Pipeline Engineering, UK Siirtec Nigi SPA Tectubi S.R.L.

Cooper Cameron Valv Italy SRL-FRM, Italy Franz Schuck GmbH (Formerly Borsig) ITAG Kitamura Valve Manufacturing Co Ltd Larsen & toubro Ltd, India Microfinish Valves Ltd, India MSA A.S. OMS Saleri PCC Ball Valves SRL Perar SPA (Enq. to T.R.P. SRL) Petrol Valves SRL Pibiviesse SPA Tormene Gas Technology SPA Virgo Engineers Ltd, India Weir Valves & Controls UK Ltd

Gate Valve, Forged Carbon Steel -

Associated Toolings India Pvt Ltd, India BDK Engineering Industries Ltd, India BHEL (Trichy), India Econo Valves Pvt Ltd, India KSB Pumps Ltd (Coimbattore), India Larsen & toubro Ltd, India Leader Valves Ltd, India Niton Valve Industries Private Ltd, India Oswal Industries Ltd, India Panchvati Valves & Flanges Pvt Ltd, India

VENDOR LIST - PIPING

Page 3 of 4

15)

Pressure Balanced Plug Valve (NFS) - FCS -

16)

Larsen & Toubro Ltd, India

Pipe - Carbon Steel to Indian Standards -

17)

Petrochemical Engineering Enterprises, India Steel Strong Valves India Pvt Ltd, India

Advance Steel Tube Ltd., India Asian Mills Pvt Ltd, India BMW Industries Ltd(Bansal Mech Works) , India Goodluck Steel Tubes Ltd, India Indus Tube Limited, India Jindal Pipes Ltd, India Jindal Saw Ltd (Kosi Works) , India Lalit Profiles & Steel Ind Ltd. , India Lloyd Metals & Engineers Ltd. , India Maharashtra Seamless Ltd, India Man Industries Ltd, India Mukat Pipes Ltd., Mukat Tanks & Vessels Ltd., India North Eastern Tubes Ltd. Pratibha Pipes & Strl Pvt Ltd PSL Limited (Nani Chirai) PSL Limited (Chennai) Ratnamani Metals & Tubes Ltd Sri Sarbati Steel Tubes Ltd Steel Authority of India Ltd Surindra Engineering Co Ltd (Rajpura), India Surindra Engineering Co Ltd (Mumbai), India Surya Roshni Ltd, India Swastik Pipes Ltd,, India The Tata Iron & Steel Co Ltd, India Welspun Gujarat Stahl Rohren Ltd, India

Air Conditioning System – package Unit -

Batliboi & Co Ltd, India Blue Star Ltd, India Emerson Network Power (I) Pvt Ltd, India Eta Engineering Pvt Ltd., India Voltas Ltd. , India

VENDOR LIST - PIPING

Page 4 of 4