Gail Gas Fabrication Pdil Spec

GAIL GAS LIMITED
(100% subsidiary of GAIL)
TENDER DOCUMENT FOR CIVIL, PIPING, ELECTRICAL AND ASSOCIATED W O R K S F O R C O N S T R U C TI O N O F N E W CNG STATION AT PANVEL- MAHARASHTRA
TENDER NO. PNMM / 4405 / E / 602
VOLUME- III OF III

ISSUED BY
PROJECTS & DEVELOPMENT INDIA LIMITED

(A GOVT. OF INDIA UNDERTAKING)
PDIL BHAWAN, A - 14, SECTOR - 1, NOIDA, G.B. NAGAR 201 301, (UTTAR PRADESH)
March 2009
Allrightsreserved
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PROJECTS & DEVELOPMENT INDIA LTD
DOCUMENT NO
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MASTER TABLE OF CONTENTS

Name of Project
: CIVIL, PIPING, ELECTRICAL & ASSOCIATED CONSTRUCTION
WORKS FOR NEW CNG STATION AT PANVEL MAHARASHTRA OF M/S GAIL GAS LIMITED
Tender Document No : Description:

1)
PNMM / 4405 / E / 602
Volume-I OF III PART A 1.0 2.0 3.0 1.0 1.0 1.0 2.0 3.0 4.0 1.0 INVITATION FOR BIDS [IFB] ACKNOWLEDGMENT CUM CONSENT LETTER SUBMISSION OF BID INSTRUCTIONS TO BIDDERS [ITB] GENERAL CONDITIONS OF CONTRACT [GCC] SPECIAL CONDITIONS OF CONTRACT [SCC] TECHNICAL ANNEXURES TO SCC (TECHNICAL) PARTICULAR JOB SPECIFICATIONS APPENDIXES TO PARTICULAR JOB SPECIFICATIONS SPECIAL CONDITIONS OF CONTRACT [SCC] COMMERCIAL PREAMBLES TO SCHEDULE OF RATES SHEDULE OF RATES & PRICE SUMMARY SHEETS
PART B PART C PART D
PART E 2) Volume-II OF III 1.0 2.0 3)
Volume-III OF III TECHNICAL SPECIFICATIONS, STANDARDS, SKETCHES, DRAWINGS &
DOCUMENTS FOR CIVIL, PIPING AND ELECTRICAL WORKS.
4405-E-602
SPECIFICATIONS, STANDARD & SKETCHES FOR CNG SATATION AT PANVEL
DOCUMENT NO. SHEET 1 OF 3
TABLE OF CONTENTS VOLUME III OF III

Name of Project
: CIVIL, PIPING, ELECTRICAL & ASSOCIATED CONSTRUCTION WORKS FOR NEW CNG STATION AT PANVEL
MAHARASHTRA OF M/S GAIL GAS LIMITED
Tender Document No. A1.
PNMM / 4405 / E / 602
CIVIL WORKS
Details of Office, Compressor foundation, Cascade & Pavement at CNG station - Panvel 4405-0000-0201
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MECHANICAL PIPING & TUBING SPECIFICATIONS & DRAWINGS

Description Doc. No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Specification for Excavation of the Trench Standard Specification For Quality Assurance System Specification for Taking over, Handling, Hauling, Stocking and Stringing of Steel Pipes. Welding Specification for Onshore Pipeline for Transportation of Gas Welding specification chart Format for PQR Specification for Repair of Pipe Corrosion Coating. Specification for Lowering In Specification for Backfilling of Trench Specification for Hydrostatic Testing (Onshore Pipelines) Standard Specification for Field Joint Coating Standard Specification for Inspection, Flushing and Testing of Specification for Purging and Commissioning the Network
4405-PNMP-TS-0903 4405-PNMP-TS-0904 4405-PNMP-TS-0905 4405-PNMP-TS-0906 4405-PNMP-TS-0907 4405-PNMP-TS-0908 4405-PNMP-TS-0911 4405-PNMP-TS-0912 4405-PNMP-TS-0913 4405-PNMP-TS-0915 4405-PNMP-TS-0916 4405-PNMP-TS-0919 4405-PNMP-TS-0920
GREENFIELD MOTHER CNG STATION AT PANVEL M/s GGL
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VOLUME III OF III Sl. Description Doc. No.
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.
Specification for Technical Records Specification for Preparation of Steel Pipes Technical Notes for Gaskets Technical Notes for Bolts & Nuts Technical Notes For Valves Technical Notes for Seamless Fittings & Flanges Technical Notes for Pipes Piping Material Specifications Valve Material Specifications Technical Specifications For Insulating Joints Technical Specifications For Stainless Steel Tubes For CNG. Specification for firefighting arrangement Specification for Flexible Fill Hose Specification for SS Ferrule Fittings Specification for SS Ball Valves Specification for laying & testing of SS tubes for CNG equipment Process & Instrumentation diagram Piping Bill of Quantities Line Schedule Plot plan- cum Equipment Layout for CNG Station General arrangement piping layout plan drawing Schematic Layout SS tubes Specification for Piping fabrication and Erection Specification for Health, Safety and Environmental (HSE) MANAGEMENT AT CONSTRUCTION SITES ENGINEERING STANDARD (PDIL) for Selection And Application Of Protective Coating
4405-PNMP-TS-0921 4405-PNMP-TS-0922 4405-PNMP-TS-0926 4405-PNMP-TS-0927 4405-PNMP-TS-0928 4405-PNMP-TS-0929 ES-6101 4405-5511-0051 4405-5511-0081 4405-PNMP-TS-0930 4405-PNMP-TS-0931 4405-PNMP-TS-0932 4405-PNMP-TS-0933 4405-PNMP-TS-0934 4405-PNMP-TS-0935 4405-PNMP-TS-0936 4405-0000-0021 4405-5511-0066 4405-5511-0090 4405-1000-0001 4405-5511-0605 4405-5511-6300 4405-PNCN-TS-0601 4405-PNCN-TS-0602 ES: 2001
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PIPELINE STANDARD AND SKETCHES

Title Typical piping drawing for existing tap off connection Pipe line Symbols Topographical symbols Existing underground pipe crossing (Type-II) Underground cable crossing Overhead power crossing Typical Sketch for Aboveground Support Typical Sketch for Insulating Kit Gasket Assembly Sketch. No. 4405-0000-1401 4405-0000-1411 4405-0000-1412 4405-0000-1417 4405-0000-1419 4405-0000-1420 4405-0000-1422 4405-0000-1424
CSl. 1. 2. 3. 4. 5. 6. 7. 8. 9.
ELECTRICAL (Drawings / Standards)

Title Single line distribution diagram Lighting & Earthing layout for CNG station Arrangement of connections of Earth conductors Typical connection details in earth pit Earth pit details Typical arrangement of earthing for Motor and start stop push button 3.8 M GI electrode for earthing GI / AL accessories for earth pit GI earth bus Sketch. No. 4405-0000-0985P 4405-0000-0986P PDS E 603 PDS E 604 PDS E 605 PDS E 606 PDS E 610 PDS E 611 PDS E 615
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SPECIFICATION FOR EXCAVATION OF THE TRENCH
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1.0 OBJECT 2.0 MATERIALS AND EQUIPMENT 3.0 ROUTE 4.0 SIZE OF THE TRENCH 5.0 CLEARING 5.1 REMOVAL OF OBSTACLES 5.2 CIRCULATION 5.3 MODIFICATIONS OF TRAFFIC 6.0 REMOVAL OF ROAD SURFACINGS 7.0 DIGGING OF THE TRENCH 8.0 SHEETING AND BRACING OR PROPPING 8.1 TRENCH 8.2 EXISTING STRUCTURES 9.0 DEWATERING 9.1 IN THE TRENCH 9.2 OUTSIDE OF THE TRENCH 10.0 JOINT HOLES 11.0 EXCAVATED MATERIAL 12.0 SIGNALLING, FENCHIGN AND LIGHTING 12.1 SIGNALLING 12.2 FENCING 12.3 LIGHTING
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1.0
OBJECT This specification refers to the excavation, clearing and finishing of the trenches in which the pipelines are to be laid.
2.0
MATERIALS AND EQUIPMENT The Contractor shall supply all materials and equipment necessary for the excavation, clearing and finishing works of the trench, for the transport of excavated earth and backfill material, for the draining of the trenches and for any equipment such as bracings, props, casings, channels and pipes required for the proper execution of the works. The Contractor shall obtain from the relevant authorities the entire necessary authorisation for using these materials and equipment.
3.0
ROUTE The route of the trench shall be marked on the ground according to the final route determined with the Engineer. Where the excavation is carried out by hand, the two edges of the trench shall be marked on the ground. Where a machine is used, one edge only shall be marked, since the width of the trench depends on the size of the trenching equipment. The route of the trench shall be such that the axis of the pipeline shall not less than one meter from the building line, unless otherwise requested by the Engineer for specific reasons. Should obstacles be encountered, the Contractor shall dig trial holes around these obstacles until a route is accepted by the Engineer. In all cases, it shall be the responsibility of the Contractor to check for the existence of any and all underground utilities along the route of the trench. Omission on the construction drawings shall not be considered as the non-existence of underground utilities or obstacles. The Contractor shall in particular make provision for any new facilities having been laid after the Construction drawings were drawn up.
4.0
SIZE OF THE TRENCH The width of the trench shall be the outside diameter of the pipe plus 0.40 meter on each side. The minimum depth of the trench shall be such as to provide a cover over the crown of the pipe as specified in the special specifications. When necessary, in case of obstacle crossings, tie-ins etc., it shall be the responsibility of the Contractor to make the trench wider and deeper than specified above in order to have sufficient working space.
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At obstacles crossings or underground utilities or works, the trench shall be excavated to a depth giving the minimum clearance specified in the specification Obstacle crossings and special passages. 5.0 5.1 CLEARING REMOVAL OF OBSTACLES The Contractor shall clear the work-site of any obstacles such as stocks of road building, materials, sight holes, temporary barracks etc., in agreement with the appropriate authorities. The Contractor shall settle the matter with the appropriate authorities, even if new obstacles appear after the construction drawings have been drawn up. 5.2 CIRCULATION The Contractor shall carry out all clearing work necessary for the free and safe circulation of pedestrians and road users. The Contractor shall ensure the free and safe trench crossing for pedestrians and vehicles. Wherever the trench is excavated along or across streets, roads and sidewalks, the Contractor shall install temporary bridges for pedestrians and vehicles as specified in the special specifications. Steel plates shall be installed on the whole length of road crossings, so that the roads crossed by the trench are now narrowed. 5.3 MODIFICATIONS OF TRAFFIC Wherever, due to the dimension of the streets or the traffic conditions, it will be necessary to modify, limit, divert or even stop temporarily the traffic, the Contractor shall deal with the Municipality and Police authorities and inform the Engineer of the arrangements agreed upon. 6.0 REMOVAL OF ROAD SURFACINGS Road surfacing shall be removed by appropriate cutters, in the case of asphalt, bitumen or cement surfacing. Cobbles, slabs, bricks, or ceramic paving-stones shall be removed with care for possible reuse. Materials unsuitable for reuse shall immediately be removed from the site as digging proceeds. Materials suitable for reuse shall tidily be piled up as directed by the Engineer.
7.0
DIGGING OF THE TRENCH The Contractor shall trench to the specified depth and width. The maximum length of open trench may be extended subject to the approval of the Engineer.
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The sides of the trench shall be cleared of any roughness which could damage the coating of the pipes during lowering-in. The bottom of the trench shall be uniformly graded and free from stones, rocks, pebbles, gravel or other objects which could damage the coating. Underground facilities, such as water pipes, electric cables, telephone cables, located with the limit of the trench shall be carefully exposed by hand excavation. The Contractor shall be liable for all damages and injuries caused to encountered utilities and shall deal with the matter with the appropriate authorities. 8.0 8.1 SHEETING AND BRACING OR PROPPING TRENCH The Contractor shall carry out the sheeting or bracing whenever required by the nature of the ground and/ or the depth of the trench, and whenever the Engineer so requires. Sheeting or bracing shall not be removed until the backfilling progress allows their removal without any risk of injury to the personnel or damage to the coating. The Contractor shall be responsible for the application of the safety regulations in force and for the consequences of inadequate or insufficient safety measures. 8.2 EXISTING STRUCTURES Any structure which may be damaged during the excavation work shall be protected. Trenches, located near electricity poles, lamp-posts or foundations shall be propped; the propping shall be kept until the end of the backfilling and left it necessary. Wherever underground lines or utilities interfere with construction work, the Contractor shall take the necessary measures to preserve the continuous use of the utilities during and after the gas lines construction work in accordance with the concerned authorities requests. The Contractor shall be responsible for the consequences of inadequate or insufficient safety measures.
9.0 9.1
DEWATERING IN THE TRENCH The Contractor shall keep the trench free from water.
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The Contractor shall provide pumps, shoring equipment and all equipment and material required to maintain the trench in good condition until the pipe is laid and the trench backfilled. 9.2 OUTSIDE OF THE TRENCH The excavated materials shall not interfere with the flow of water when the trench passes alongside a road; this flow shall be maintained by a drain or if necessary by deviating the water to the opposite gutter. The excavation of the trench shall not interrupt the flow of water. At each street crossing, a gutter shall be tunnelled and underpinned by means of planks. If the gutter cannot be kept in use, it shall be replaced by a duct. 10.0 JOINT HOLES Where tie-ins are to be made in the bottom of the trench, the Contractor shall dig joint holes in order to allow unrestricted welding, coating and wrapping as well as the relevant inspections. 11.0 EXCAVATED MATERIAL The excavated material shall be placed in such a way as to avoid any inconvenience to property owners, or interference to the circulation of pedestrians or vehicles as well as to the operation of nearby installations. The excavated material shall be piled up in such a way that they enable the watering of the trees. No excavated material shall be piled up in the road crossings. To prevent the excavated stone and earth from falling into the trench, a strip 20 cm wide shall be left clear between the edge of the trench and the bottom of the pile of excavated earth. This width may be increased, according to the nature of the ground and the atmospheric conditions. Wherever necessary, the Engineer may require the excavated material to be removed from the site and to be kept at a dump yard until the trench is to be back filled and to be brought back to the site for backfilling. When the excavated material is judged by the Engineer to be unsuitable for re-use, the Contractor shall remove it from the site as the digging of the trench proceeds and shall supply in its place suitable material approved by the Engineer.
12.0 12.1
SIGNALLING, FENCING AND LIGHTING SIGNALLING
12.1.1 Site Identification
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Each site shall be provided with an identification board mentioning the reason for the work and the names of the Company, the Contractor and the Consulting Engineer, as stipulated in the special specifications. 12.1.2 Traffic Signals At both ends of the trench, the Contractor shall install 2 traffic signs, one immediately close to the trench and the other ahead as required by the Engineer. 12.2 FENCING The Contractor shall fence all working areas. He shall also fence both sides of temporary bridges, when required by the Engineer. 12.3 LIGHTING The Contractor shall install lights around all working areas, in accordance with the special specifications. The voltage shall conform to the safety regulations in force. The Contractor shall install signalling, fencing and lighting of all trial holes, trench sections and other excavations. The Contractor shall provide watchmen wherever deemed necessary for the safety of the public and of the workers, in particular as regards working sites, on site material stockage, temporary dumping yards etc.
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STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM
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CONTENTS
1. 2. 3. INTRODUCTION SCOPE OF WORK BY CONTRACTOR QUALITY ASSURANCE SYSTEM REQUIREMENTS A N N E X U R E S: I II III GUIDELINES TO BIDDERS FOR COVERAGE OF DOCUMENTS GLOSSARY OF TERMS USED IN THE SPECIFICATION PROFORMA FOR QUALITY PLAN
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1.0
INTRODUCTION This specification established the Quality Assurance requirements to be met by the TURN-KEY Bidder during execution of CONRTRACTED SERVICES. In case of any conflict between the requirements of this specification and other documents such as technical specifications, contract conditions etc. the latter shall generally take precedence. The Contractor shall notify PDIL/Owner or all such conflicts for final resolution. Requirements stipulated in this specification conform to ISO: 9000, 9001, 9002, 9003 and 9004.
2.0 2.1
SCOPE OF WORK BY CONTRACTOR Prior to the award of contract: The following documents shall be submitted along with the bid for evaluation:
2.1.1 Quality Assurance Manual and/or Departmental Activity Control Manual. 2.1.2 Quality Plans (Tentative) Guidelines to Bidder for coverage of above documents are given in Annexure-I. A Proforma for Quality Plan is enclosed as Annexure-III. 2.2 After the award of contract (prior to start of job) The Contractor shall obtain approval on his Quality Assurance manual and/or Department activity control manual and Quality Plans. The Contractor shall participate in the pre-start meeting with PDIL/Owner to finalize "Quality Plans" as regards to the following: 2.3 Standard practices specified by the Contractor Hold, Witness and Verification point. PDIL/Owner's review/audit requirements.
During job execution
2.3.1 Implement approved Quality Assurance Programme including but not limited to Performance of internal quality audits, reparation of audit reports and submission or PDIL/Owner's review. Generation of Q.A. records (mostly inspection and test plans) as per Quality Plan and submission for PDIL/Owner's review.
2.3.2
Facilitate PDIL/Owner in the quality audit at his works.
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2.3.3 Certify "QA Programme" documents of subcontractor and submission to PDIL/Owner for review. 2.3.4 Carry-out audits/inspection at sub-contractor's works as per approved Q.A. programme and submit the reports for PDIL/Owner's review. 3.0 3.1 QUALITY ASSURANCE SYSTEM REQUIREMENTS Requirements stipulated in this specification shall be fulfilled by the Contractor/Subcontractor. All other features of QA System (not specified here-in) shall be inline-with any of the following standards (latest revisions). IS : 10201 ISO : 9000, 9001, 9002, 9003, 9004 BS : 5750 ANSI/ASQC : Q90, Q91, Q93, Q94 3.2 The Contractor shall ensure that the quality system is clearly understood and faithfully implemented at all levels in his organization. The Contractor shall develop quality consciousness among all personnel working for the contract. Non-conformance handling (internal sources) :
3.3
3.4
Non-conformance brought out by Contractor's/Sub-contractor's own review/audit shall be resolved by Contractor's/Siub-contrtactors' themselves. One level higher than those responsible to carry out the activity shall resolve the non-conformance. Such resolution shall be in full knowledge of Departmental Manager. Corrective action shall be initiated at the earliest. Report of such resolution shall be submitted to PDIL/Owner for information. 3.5 Non-conformance Handling (External sources) : Non-conformance brought out by PDIL/Owner through any of the following: Technical Reviews Q.A. Reviews & Surveillance Inspection and External Audit (PDIL/Owner);
Shall be resolved by the Contractor/Sub-contractor. Such corrective actions shall be submitted to PDIL/Owner for review. However, corrective action shall be initiated at the earliest. 3.6 The Contractor shall evolve a comprehensive system of planned and documented audit to verify whether various performed activities comply with detailed procedures. Specifications, guidelines etc. and to determine the effectiveness of QUALITY SYSTEM. Scope of such internal audits shall be furnished to PDIL/Owner for review. Verifiable documents shall be generated during audit and submitted periodically to PDIL/Owner for review. Audit shall be carried out by independent engineers not responsible for execution of the activity to be audited.
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3.7
Throughout all stages of the scope of contract, the Contractor's procedures, documents, activities, Products and services and those of his Sub-contractors shall be subjected to Quality surveillance and audit by PDIL/Owner. Such surveillance and audit are optional and shall not relieve the Contractor of his contractual obligations and liabilities. The Contractor shall submit all quality records (generated during activity execution) and audit results on well laid formats/proformae for PDIL/Owners review. The rights of such review are reserved by PDIL/Owner. PDIL/Owner may review it in full, parts or selectively. However, complete correctness of the Q.A. records shall be the sole responsibility of the Contractor irrespective of its review by PDIL/Owner. The Contractor shall get similar Q.A. system implemented at his Sub/contractors' works/office. Q.A. records from the Sub/contractor shall be reviewed and certified for compliance by the Contractor before submitting to PDIL/Owner for information. Contractor shall carry-out audits at Sub-contractors' office/works and shall submit the report to PDIL/Owner for information. All Personnel shall be assigned tasks commensurate with their qualification. Specialized operators shall be qualified and certified. The Contractor shall have a system for identifying personnel training needs in line with ISO: 9004.
3.8
3.9
3.10
3.11
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ANNEXURE-I GUIDELINES TO BIDDER FOR COVERAGE OF DOCUMENTS 1.0 QUALITY ASSURANCE /DEPARTMENTAL ACTIVITY CONTROL MANUAL This document is applicable to all the contracted activities performed Contractor's/Sub-contractors' works/office. The document shall cover the following: Policy statement of the organization on Quality Assurance. Company Organizational Structure, including Q.A.Organisation Structure. Personnel responsibilities (as regards Q.A.) Periodic Q.A. System review programme by higher management. System & basis of Quality cost estimation. Various operational procedures (Departmental and activity wise). These procedures are not required to be submitted along with the bid. The Contractor shall implement these procedures and maintain them in auditable formats such that these are available for PDIL/Owner's review any time during the job execution. Given below is the list of some important procedures. The list is not exhaustive/complete and does not mean to limit all the procedures required for the job execution. General Document control Co-ordination Non-conformance resolution Change of scope Output identification and traceability Feed-back processing QA system Quality cost estimation Internal audit at
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Design: Design basis finalization Detail design - performing, checking, review and approval Drafting - performing, checking, review & approval Technical specification preparation checking, review & approval Engineering for procurement Finalized over-all design review Procurement Vendor short listing Incoming material control Welding qualification and repair Manufacturing/fabrication process control Applicable non-destructive examination Coating/lining Preservation Post-weld heat treatment Packaging and dispatch control Transportation Inspection/Test Plans for all specific and mandatory tests (as per drawings an Codes) with clear indication of witness, verification and hold points. Construction: Pre-construction activities viz. incoming material control, receipt control etc. Job construction Welding qualification and repair Inspection/Test Plans for all specified and mandatory tests (as per drawings & codes) with clear indication of witness, verification and hold points. Commissioning Pre-commissioning activities Inspection/Test** Plans with witness, verification and hold points.
**- All inspection and Test Plans are required to be submitted for finalization and approval by PDIL/Owner immediately after award of the contract (before prestart meeting).
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2. O QUALITY PLAN These documents, mostly in tabular formats (See attached proforma for Quality Plan) define the specific quality practices and flow of every identifiable activity of a department. All departments concerned with the bid package must be covered. These plans must tentatively indicate: For Design Activity description Preparation, checking, review and approval requirements Code of conformance (applicable standard and specification number) Applicable procedure number Internal audit scope Q.A. data/records produced
For Procurement & Construction Activity description Procedure number/inspection and Test Plan number Conformance code Testing and inspection code Type of surveillance Internal audit scope
For Commissioning: Activity Description Procedure/Inspection and Test Plan number Type of surveillance Internal audit scope
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ANNEXURE-II
GLOSSARY OF TERMS USED IN THE SPECIFICATION 1. A point designated by PDIL/Owner in the approved Quality Plan submitted by the Contractor in pre-start meeting which requires inspection/verification and acceptance by PDIL/Owner before any further processing is permitted. The Contractor shall not process the activity/item beyond a hold point, without written approval by PDIL/Owner except where prior written permission for further processing is available. 2. WITNESS POINT An activity designated by PDIL/Owner which requires witnessing by PDIL/Owner as the activity is performed. After proper notification has been provided (notification modalities and period shall be finalized in pre-start meeting) the Contractor is not obliged to hold further processing if PDIL/Owner is not available to witness the activity or does not provide comments before the date notified. Basis of acceptance shall be as per relevant technical specification. 3. VERIFICATION POINT Point where PDIL/Owner plans to audit, monitor or witness on in-process activity. The Con tractor is not obliged to provide any advance written notification of these points. Basis of acceptance shall be as per relevant technical specification. 4. QUALITY SURVEILLANCE Monitoring or making observations to verify whether or not material items or services conform to specified requirements. Surveillance activities may include audit, inspections, witness of testing, review of Quality documentation, personnel qualifications etc.
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5.
Q.A.RECORDS: Documents which demonstrate achievement of required quality and verify effective operation of Quality System, viz, 6. Inspection reports Test data/Inspection & Test Plans Qualification reports Validation reports Audit reports Material review reports Calibration data Quality cost report
QUALITY AUDIT: A systematic examination of the acts and decisions by people with respect to quality in order to independently verify or evaluate and report degree of compliance to the operational requirements of the quality programme, or the specifications or contract requirements of the product or service.
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ANNEXURE-III COMPANY NAME: GENERAL TABLE - I QUALITY PLAN DEPARTMENT: PROJECT NAME: PERFORMING FUNCTIONS INSPECTION FUNCTIONS TESTING & INSPECTION CODE OF AUDIT FUNCTION AUDIT OWNER'S REVIEW/ AUDIT REQUIREMENT
SAMPLING PLAN
CODE OF CONFORMANCE
TYPE (APPROVAL) SURVEILLANCE
ACTIVITY DESCRIPTION
PERFORMER
PROCEDURE NUMBER
REVIEWER/ APPROVER
INTERNAL SCOPE
CHECKER
4405-PNMP-TS-0905
TECHNICAL SPECIFICATION FOR TAKING OVER, HANDLING, HAULING, STOCKING AND STRINGING STEEL PIPES
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CONTENTS
1.0 2.0 3.0 4.0 OBJECT EQUIPMENT TAKING OVER PIPES AND PIPELINE ACCESSORIES HANDLING AND STOCKING PIPES AND PIPELINE ACCESSORIES. BARE PIPES COATED PIPES PIPELINE ACCESSORIES STRINGING PIPES AND PIPELINE ACCESSORIES USING CROP-ENDS INVENTORY RECOVERY AND STORAGE
4.1 4.2 4.3 5.0 6.0 7.0 8.0
1.0
OBJECT This specification refer to the taking over, handling, hauling, stocking and stringing of pipes and equipment to be used in the construction of the distribution network.
2.0
EQUIPMENT The Contractor shall supply the equipment which is required for the loading, hauling, unloading, stocking and protecting the pipes and pipeline equipment. The equipment used by the Contractor shall be adapted to the condition of the roads and tracks, the relief of the land, the characteristics of the pipes and the construction schedule.
3.0
TAKING OVER PIPES AND PIPELINE ACCESSORIES
The Contractor shall check the packing lists and send them to the Engineer with acceptance or reservation for shortage or damage. Should no reservation be mentioned in these documents, the Engineer may consider that the Contractor has received and accepted all pipes and pipeline accessories listed in these documents. Any missing or damaged pipe of pipeline accessory shall be replaced or repaired by the Contractor. All demurrage charge incurred because of a delay in loading the pipes or pipeline accessories shall be borne by the Contractor. 4.0 HANDLING AND STOCKING PIPES AND PIPELINE ACCESSORIES The Contractor shall take all the necessary steps and precautions to ensure that the bare or coated pipes are not damaged during loading, hauling, unloading and stocking. 4.1 BARE PIPES The pipe shall be handled with Care in order to prevent damage. The use of steel cables of chains wound round the pipes of steel hooks is strictly prohibited. Nerveless lifting hooks equipped with a bent brass copper plate placed within each pipe end may be used when approved by the Engineer. During haulage the pipes shall be wedged and protected in such a way as to prevent any distortion, flattening or damage to pipe ends and as to have no contact with the adjacent pipe. The maximum number of layers of bare pipes, both on the vehicles used for hauling and in the ground round stock yard shall be determined in order to prevent permanent distortion and flattering.
The pipe layers shall be wedged to avoid any accidental rolling. If not flat, the stock yard shall be leveled by the Contractor. The pipes shall be supported from the ground by skids. 4.2 COATED PIPES In addition to the precautions here above mentioned for the bare pipes, the Contractor shall handle and stock the coated pipes under the following conditions. . 4.2.1 Handling The use of claws, pliers, chains, slings, and ropes for crane lifting is prohibited. The recommended devices are twisted hemp, plastic or leather straps, at least100mm wide and a swing-bar for limiting the flexion of the pipes. The wood planks used for handling shall be perfectly smooth or coated with plastic strips on both faces. When the weather is hot the Contractor shall handle the coated pipes during the cool hours of the day. The Contractor shall avoid handling the coated pipes when the ambient temp. is 0C and below. 4.2.2 Stocking The contractor shall not stock on the same pile - coated pipes of different diameters - crossed layer of coated pipes The pipe shall be support clear from the ground by skids and wedges, either coated with neoprene strips, 25 to 30 cm wide, or having a padding approved by the Engineer. In the Stock yard, the maximum number of layer of coated pipes for a pile is as follows: Nominal pipe diameter Number of layers
25mm 32mm 50mm 80mm
10 8 6 2
Between the pipe layers; the Contractor shall place neoprene strips, matting or any other flexible material approved by the Engineer:
4.3 PIPELINE ACCESSORIES The pipeline accessories, such as valves, insulating, flanges, etc shall stocked under temporary shelters such as tarpaulins, nylon sheets and kept clear from the ground by wood planks or any approved isolating devices. Both ends of valves should insulate dirt and moisture from entering. Flanges shall be temporarily sealed by wooden plugs or plastic caps to prevent dust. 5.0 STRlNGING PIPES AND PIPELINE ACCESSORIES The pipes shall be STRUNG the edge of the trench in such a way that: They cause no inconvenience to the road and street traffic and no damage to roads and streets. They are not in danger or being damaged neither by Contractors machines nor by road users vehicles. The Contractor shall be responsible for stringing the pipes and pipeline accessories at the proper location in accordance with the construction drawings. The strung coated pipes shall be kept clear from the ground by padded skids.
The valves, Insulation, flanges, cathodic protection and regulator equipment shall be brought from the stock yard to the site at the time of their insulation. Tile pipes and pipeline accessories that transport of that are to installed in flooded areas likely to be flooded, shall not be supplied until the moment of assembly. 6.0 USING CROP-ENDS The Contractor shall insure transport of any usable crop-ends to the locations where they can be used, taking Care that are no more than three {3) welds over a ten (10) meter straight length of pipeline.
The length of a crop-end pipe considered as usable shall be at least: - 0.50 m for pipe having a nominal diameter of 200 mm and less: - Two diameters for pipes having a nominal diameter of 250 mm and over The maximum total length unusable crop ends to the (pipe rejected for reasons attributed to the Contractor and pipes used for welding process approval test and welder qualification tests) shall be fixed at three per thousands of the total length per category of pipe supplied by the Company. The surplus of unusable lengths shall be the Contractor.
7.0
INVENTORY The Contractor shall for each category of pipe keep a permanent inventory of the pipeline accessories he has received. After the execution of the works and for the pipes supplied by the Company the Contractor shall draw up a list of unused pipes and usable crop ends. This document shall be part of the technical records to be given to the Engineer.
8.0
RECOVERY AND STORAGE When the pipes have supplied by the Company, the pipes remaining after the construction of the pipelines as well as the usable crop-ends shall be marked by the Contractor hauled and stored in a place determined by the Engineer. The parts stored shall be classified by category according to their characteristics (diameter, thickness, grade of steel). These operations must be finished by the date of Completion of the Work.
4405-PNMP-TS-0906
WELDING SPECIFICATION FOR ONSHORE PIPELINE FOR TRANSPORTATION OF GAS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREP D
REVWD
APPD
CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. SCOPE APPLICABLE CODES AND STANDARDS BASE MATERIAL WELDING CONSUMABLES EQUIPMENT & ACCESSORIES WELDING PROCESSES BEVEL CLEANING AND BEVEL INSPECTION ALIGNMENT AND SPACING WEATHER CONDITIONS WELDING HEAT TREATMENT INSPECTION AND TESTING REPAIR OF WELDS DESTRUCTIVE TESTING ULTRASONIC INSPECTION RADIOGRAPHY ELECTRODE QUALIFICATION TEST RECORD STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION WELDING PROCEDURE QUALIFICATION TEST RECORD WELDER QUALIFICATION TEST RECORD WELDERS IDENTIFICATION CARD RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
ANNEXURE-1 ANNEXURE-2 ANNEXURE-3 EXHIBIT-A EXHIBIT-B
EXHIBIT-C EXHIBIT-D EXHIBIT-E EXHIBIT-F 1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of welded joints of carbon steel piping systems connected with the pipeline 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. Attachments of castings, forgings flanges and other supports to pipes. Welded manifold headers and other sub-assemblies. Welded branch connections. Joints in welded / fabricated piping components. The attachments of smaller connections for vents drain drips and other instrument tapings.
b) c) d) e) f)
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) b) Code for Gas Transmission and Distribution Piping Systems ANSI B 31.8. Standard for welding of Pipelines and Related Facilities, API 1104, ASME Sec.IX Specification for welding Electrodes and Filler Materials ASME Sec. II C Non-Destructive examination, ASME Sec.V
c) d) 3.0
BASE MATERIALS a) 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 electrodes, oxygen, acetylene etc. and these shall bear the approval of the COMPANY. The welding electrodes, filter 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. The electrode shall suitable for the welding process recommended and the base metal used. Physical properties of the welds produced by an electrode 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 adopted. The choice of electrode shall be made after conducting the required tests on the electrodes as per relevant standards, and shall be the sole prerogative of the COMPANY. The CONTRACTOR shall submit batch test certificates from each electrode manufacturers giving details of physical and chemical tests carried out by them for each batch of electrodes to be used. Electrode Qualification test records shall be submitted as per the Exhibit A (attached) in respect of the electrodes tested by the CONTRACTOR for obtaining the approval of the COMPANY. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. The electrodes removed from the containers (except cellulosic coated electrodes) shall be kept in the holding ovens, at the temperature recommended by the electrode manufacturer. Ovens shall be used for the low hydrogen electrodes only. Out of the oven time of electrodes before they are consumed shall not exceed the limits recommended by the electrode manufacturer. The electrodes shall be handled with care to avoid the any damage to the flux covering. Different grades of electrodes shall be stored separately. Cellulosic electrodes used shall however be used as per the specific recommendations of manufacturer. The electrodes used shall be free from rust, oil, grease, earth and other foreign matter, which affect the quality of welding. Shielding Gas The composition and the purity of shielding the gas when required by the welding processes other than shielded metal arc welding, when permitted by the COMPANY shall bear the approval of the COMPANY. Where appropriate, gases or gas mixture of the following quality shall be used.
b)
c)
d)
e)
f)
g)
h)
1. 2. 3.
Argon gas complying with BS 4265 Carbon dioxide gas complying with type 1 specified in BS 4105 Gas mixtures that have been proved to be satisfactory as a result of procedure approval tests. When a gas mixture is used, which has specified additions, e.g. 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 -30oC or lower.
5.0
EQUIPMENT & 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 heat treatment, including transformers, thermocouples, pyro-meters, 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. Redoing of any work necessitated by faulty equipment or operation used by the CONTRACTOR will be done at his own expense.
5.2
6.0 6.1
WELDING PROCESSES Welding of various materials under this specification shall be carried out using Shielded Metal Arc Welding process (SMAW) with the approval of the COMPANY. The welding processes to be employed are given in the welding specification chart attached along with other project data sheets. Any deviation desired by the CONTRACTOR shall be obtained through the express consent of the COMPANY. Automatic process shall be employed only with the express approval of the COMPANY. The welding procedure adopted and the consumables used shall be specifically approved. A combination of different welding processes or a combination of electrodes 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. BEVEL CLEANING / BEVEL INSPECTION The Line Pipe supplied by 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 his special welding
6.2
6.3
6.4
7.0
technique, shall be carried out by the CONTRACTOR at his own cost. Before welding, all the rust and the foreign matter shall be removed from the bevelled ends by power operated tools. This shall be effected 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 his stage. If any of the ends of the pipe joints are damaged to the extent that, in the opinion of the COMPANY, satisfactory weld spacing cannot be obtained and local repair by grinding cannot be successfully done, the damaged ends shall be cut and bevelled to the satisfaction of the COMPANY, with an approved bevell8ing machine. 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 from the line to the satisfaction of COMPANY. On pipes, which have been cut back, a zone extending 25 mm back from the new field bevel, shall be ultrasonically tested to the requirement of the line pipe specification to ensure freedom from laminations. The new bevel shall be 100% visual and 100% dye penetrate / MPI tested. A report shall be written for all the testing and records kept. 8.0 ALIGNMENT AND SPACING Immediately prior to line-up CONTRACTOR shall inspect the pipe ends inside and outside for damage, dents, laminations etc. Pipe for welding shall be set up, correctly spaced, allowing for the temperature changes during welding. In correct alignment shall in no circumstances be sprung in to 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 along side the ditch with the pipe supported on skids and pack pads or other suitable means approved by COMPANY, at least 500 mm above the ground unless approved by the COMPANY in specific cases. Seam orientation of welded pipe shall be selected to ensure that at the circumferential welds, the longitudinal welds shall be staggered in the top 90o 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 clamp and rotation of the pipes to the best fit. For pipe of same nominal wall thick ness the offset shall be exceed 1.6 mm. he offset may be checked from 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 any other weld. Cold dressing is permissible only in cases of slight misalignment and may only be carried out with a bronze headed hammer. Hot dressing shall not be permitted. When welding pipes of different wall thickness (as directed by COMPANY) a special transition piece shall be used. This shall have a minimum of 1:4 taper. The welds shall be subject to both ultrasonic and radiographic inspection.
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 10and above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe 10etc.) where it is impossible to use internal clamps, an external line-up clamp may be 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 remaining adequately supported on each side 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 a protection no welding shall be carried out. The completed welds shall be suitably protected in case of bad weather conditions. 10.0 10.1 WELDING Root Pass a) The root pass shall be made with the electrodes / filler wires recommended in the welding specification chart attached along with the other project data sheets. The size of the electrodes used shall be as per the approved welding procedure. Position or roll welding may be permitted. Separate procedures shall be submitted and qualified for up hill, down hill, vertical 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 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.
b)
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 3 mm wherever not specified by the applicable code.
d)
Any deviations desired from the recommended welding technique and electrodes indicated in the welding specification chart shall be adopted only after obtaining express approval of the COMPANY. Welding shall be continuous and uninterrupted during a pass. On completion of each run, craters, welding irregularities, slag etc. shall be removed by grinding and chiselling. While the welding is in progress care shall be taken to avoid any kind of movement of the components, shocks, vibration and stresses to prevent occurrence of weld cracks. Fillet welds shall be made by shielded metal arc welding process irrespective of the thickness and class of piping. Electrode size shall not exceed 3.25 mm diameter for the socket joints. At least two passes shall be made on the socket weld joints. Penning shall not be used.
e) f)
g)
h)
i) 10.2
Joint Completion In case of manual welding, the first pass shall be carried out by a minimum of two welders, working simultaneously and so placed as to cause minimum distortion of the pipe. The number of welders and allowable welding sequences shall be, as those laid down in the qualified welding procedure specification. 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 qualified welding procedure specification. 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 above. Before starting the second pass, the first pass shall be cleaned and flatted with rotating grinders. The interruption between completion of the first pass and starting the second pass shall be as stated in the procedure specification, normally not exceeding four minutes. For crack prevention a top and bottom reinf9orcement of at least one electrode shall be applied before lowering the pipe on the skid. The welding speed selected shall enable production of a beaded which is sufficiently thick and which shows no 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, so allowing
the joint to cool down, provided that 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 100oC 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 so as to reduce the possibility of inclusions. The electrode 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 welding cable round and the pipe shall be removed by grinding in accordance with a procedure approved by the COMPANY and the repair checked by ultrasonic, radiographic, magnetic particle or dyepenetrant tests which the COMPANY fees necessary. The pipe wall thickness after grinding shall not be less than the minimum thickness limit 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. These requirements apply not only to completed welds but also to the bare strip at least so wide as to allow full skid examination at both ends of the pipe to allow a good ultrasonic inspection when it is required. 11.0 11.1 HEAT TREATMENT Pre-heating a) Preheating requirements for the various materials shall be as per the welding specification chart attached along with other project data sheets. Preheating shall be performed using resistance or induction / heating methods. Preheating for tie-in welds, repair welds or welds at point spreads may be done using a propane gas burner ring with prior approval from COMPANY. The Contractor may be asked to demonstrate the effectiveness of the arrangement. 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. 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.
b)
c)
d)
11.2
Post Weld Heat Treatment
a)
Post weld heat treatment, wherever required for joints between pipes and fittings, pipe body and supports shall be carried out by the CONTRACTOR at his expense as per the relevant specifications, applicable standards and the instructions of the COMPANY. The heat treatment of welded joints shall be carried out as per the requirements laid down in ANSI B31.8 and other special requirements mentioned in welding specification chart. The CONTRACTOR shall submit for the approval of the COMPANY , well before carrying out actual heat treatments the details of the post weld heat treatment procedure, as per Exhibit Battached, that he proposes to adopt for each of the materials / assembly / part involved. Post weld heat treatment shall be done in a furnace or by using an electric resistance or induction heating equipment, as decided by the COMPANY. While carrying out local post weld heat treatment, technique of application of heat must ensure uniform temperature attainment at all points of the portion being heat treated. Care shall be taken to ensure that width of heated band over which specified post weld heat treatment temperature is attained is at least as that specified in the relevant applicable standards / codes. The width of the heated band centred on the weld shall at least be equal to the width of weld plus 2(50 mm). The temperature gradient shall be such that the length of the material on each side of the weld, at a temperature exceeding half the heat treatment temperature, is at least 2.5 rt where r is the bore radius and t is the pipe thickness at the weld. Throughout the cycle of heat treatment, the portion outside the heat band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at the exposed surface of pipe. For this purpose temperature at the exposed surface of the pipe shall not be allowed to exceed 400oC. The temperature attained by the portion under heat treatment shall be recorded by means of thermocouple pyrometers. Adequate number of thermocouples shall be attached to the pipe directly at equally spaced locations along the periphery of the pipe joint. The minimum number of thermocouples attached per joint shall be 2 up to 10dia and 3 for 12dia and above. However, the COMPANY can increase the required minimum number of thermocouples to be attached if found necessary. Automatic temperature recorders, which have been suitably calibrated, shall be employed. The calibration chart of each recorder shall be submitted to the COMPANY prior to starting the heat treatment operation and its approval shall be obtained. Immediately on completion of the heat treatment, the post weld heat treatment charts / records along with the hardness test results on the weld
b)
c)
d)
e)
f)
g)
h)
i)
j)
joints (whenever required as per the welding specification chart) shall be submitted to COMPANY for its approval. k) Each joint shall bear an identification number, which shall be maintained in the piping sketch to be prepared by the CONTRACTOR. The joint identification number shall appear on the corresponding post weld heat treatment charts. The same identification numbers shall also be followed for identification of corresponding radiographic films. The chart containing the identification number and the piping sketch shall be submitted to the COMPANY in suitable folders. Vickers hardness / Brinnel hardness of the heat affected zone as well as of the weld metal, after heat treatment shall be measured using a suitable hardness tester and shall not exceed the maximum hardness specified in the welding specification chart. The weld joint shall be subjected to reheat treatment, when hardness measured exceeds the specified limit, at the CONTRACTORS own expense. The CONTRACTOR shall arrange for the hardness testing and shall maintain the records of all the joints tested. These records shall be checked by the plant COMPANYS inspector.
l)
m)
12.0 12.1
INSPECTION & TESTING General a) The Companys Inspector shall have free access to all the concerned areas, where the actual work is being performed. The CONTRACTOR shall also afford the COMPANYS inspector all means and facilities necessary to carry out inspection. 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 (but not limited to) the following objectives. 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 in conformity with the relevant specifications and codes of practice followed in pipe construction. CONTRACTOR shall intimate sufficiently in advance the commencement of the qualification tests, welding works and acceptance tests, to enable the COMPANYS INSPECTOR TO BE PRESENT TO SUPERVISE THEM.
b)
i)
ii) iii) iv)
c)
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 CONTRACTOR SHALL SUBMIT THE WELDING PROCEDURE SPECIFICATIONS IN FORMAT AS PER Exhibit-C(attached) immediately after the receipt of the order. COMPANYS inspector will review, check and approve the welding procedure 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 COMPANYS Inspector for approval immediately after completing the procedure qualification test and at least 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 radiography, macro / micro examination, hardness tests, dye penetrant examination charpy vnotch etc. shall be carried out on the specimens. It shall be the responsibility of the CONTRACTOR to carry out all the tests required to the satisfaction of the COMPANYS Inspector. The destructive testing of welded joints shall be as per Annexure-I.
b)
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. The butt weld test pieces of the qualification test shall meet the radiographic test requirements specified in Clause 12.5 and Annexure-3 of this specification. The Companys inspector shall witness the test and certify the qualification of each welder separately. Only those welders who have been approved by the COMPANYS inspector shall be employed for welding. CONTRACTOR shall submit the welder qualification test reports in the standard format as shown in Exhibit D and obtain express approval before commencement of the work. It shall be the responsibility of CONTRACTOR to carry out qualification tests of welders. The welders shall always have in their possession the identification card as shown in Exhibit-E and shall produce it on demand by the COMPANYS Inspector. It shall be the responsibility of the CONTRACTOR to issue the identity cards after the COMPANY has duly certified it. No welder shall be permitted to work without the possession of identity card. 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.
b)
c) d)
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 standard / code. 12.5 Non-destructive Examination. The non-destructive examination shall mainly consist of examination using x-ray radiography as detailed in Annexure-3. Radiographic examination of one hundred percent (100%) girth welds will be required by the COMPANY. 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 radiographic 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. 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) When 20 mm or more are cut from the pipe end as supplied, the ends shall be ultrasonically inspected for an additional length of 20 mm to assure no laminations exist. When welds are repaired When in the opinion of COMPANY, ultrasonic inspection is required to confirm or clarify defects indicated by radiography. Welding of transition piece of pipe.
b) c)
d)
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 Companys discretion. All fillet and grove welds other than those radio graphed shall be subjected to dye penetrant/MP inspection. The non-destructive test system used for inspecting welds must be approved by the COMPANY. 12.5.1 Acceptance criteria Weld quality as judged on the basis of the acceptability criteria mentioned below: i) Any weld, which as a result of radiographic 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 article shall be considered defective and shall so be marked with an identification point marker. 1 ii) In addition to the API 1104 the weld containing cracks including crater cracks, roots defects (like lack of fusion, lack of penetration & Burn though etc.) Regardless of size are not acceptable.
Suitable records shall be maintained by the CONTRACTOR as desired by the COMPANY on the day to day work done on welding radiography, ultrasonic testing. The CONTRACTOR shall present the records of the COMPANY on day-to-day basis and whenever demanded, for approval. 12.6 Destructive Testing The COMPANY has the authority to order the cutting of up to 0.1 % of the total number of welds completed for subjecting to destructive tests at no extra cost to COMPANY. The destructive testing of weld joints shall be made as per Annexure-I. In addition, welds already cut out for defects for any reason may also be subjected to destructive testing. The sampling and the re-execution of welds shall be carried out by the CONTRACTOR at his own expense. If the results are unsatisfactory, welding operations shall be suspended and may not be restarted until the causes have been identified and the COTNRACTOR has adopted measures, which guarantee acceptable results. If it is necessary in the COMPANYs opinion the procedure shall be re-qualified. The weld joint represented by unsatisfactory welds shall stand rejected unless investigation proves otherwise. 13.0 13.1 REPAIRS OF WELDS 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. Welder shall be qualified in advance for repairs. The root pass, the repairs opening the root, shall be replaced by the vertical uphill technique. The procedure shall be proven by satisfactory procedure test to API-1104 including the special requirements for the specifications, and shall also be subjected to metallographic examination, hardness surveys and Charpy tests to determine the effects of repair welding on the associated structure. Root sealing or single pass repair deposit shall not be allowed. Internal root defects shall be ground thoroughly and welded with a minimum of two passes. However, while grinding the repairs, care shall be taken to ensure that no grinding marks are made 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 re-radio graphed. A 100 % ultrasonic test 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. 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 clause, as defined by API1104 and this specification, repairs within these limitations are permitted. Defects in the filling and capping passes shall be repaired preferentially.
ANNEXURE-1 1.0 1.1 DESTRUCTIVE TESTING OF WELDED JOINT BUTT WELDS Preparation Having passed the visual and the non-destructive inspection, the test weld shall be subjected to mechanical test. 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. Weld specimens shall be taken from the positions indicated in Fig.1 & 1A of this specification from areas as free from defects as possible; for this reason it is necessary to take the previous non-destructive tests into account. The minimum number of tests to be carried out is given in Table-1 of this specification. The tests 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. 2.0 TENSILE STRENGTH Specimens shall be taken from the position indicated in fig.1 & 1A of this specification. Two ISO type specimens and two API type specimens shall be taken. The ISO test specimens and shown in fig-2 of this specification. 1.2.1 Method The test shall be carried out in accordance with ISO 375.
TABLE 1
PIPE, SIZE, OUTSIDE DIAMETER INCHES UNDER 2 2 TO 4 INCLUDING OVER LESS 12 12 OVER 4 THAN AND
NUMBER OF SPECIMENS TENSILE API 0 0 2 ISO 0 0 0 NICK BREAK ROOT BEND 2 2 2 FACE BEND SIDE BEND MACRO HARDNESS IMPACT TOTAL
WALL THICKNESS INCH (12.7 MM) AND UNDER 2 2 2 0 0 2 0 0 0 0 0 2 0 0 2 0 0 12 4 4 24
24
44
WALL THICKNESS OVER INCH (12.7 MM) 4 AND SMALLER OVER 4 LESS THAN12 12 OVER AND 0 2 2 0 0 2 0 2 0 2 2 0 0 2 0 2 0 12 4 24
24
44
1.3.0 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 bed to a maximum depth of 1.5 mm, measured from the surface of the weld bead. 1.4.0 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 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 times (25:1). The COMPANY may ask for a macrograph with 5 times (5:1) magnification, for DOCUMENTATION purposes. 1.4.3 Requirements Under macroscopic examination, the welded joints shall show good penetration and fusion, without any defect exceeding the limits stated in the evaluation criteria of the nick bream test. 1.5.0 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 mm below the surface at both side of the weld. In the weld metal a minimum of 6 indentations equally spaced along with 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 metal. Reference is made to Fig.3 of the specification. The indentations are to be made in the 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 R 146 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 hardness values contained from the heat-affected zone shall not exceed 10 HV with respect to the average hardness of the values obtained for the base metal. If these additional tests give hardness within the specification limit the slightly higher value may be accepted.
1.6.0 CHARPY V-NOTCH IMPACT TEST 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 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 : Nominal wall thickness (mm) Over 12 Over 9.5 and up to 12 From 7 up to 9.5 Less than 7 1.6.2 Test Method The test shall be carried out as indicated in ISO R 148 Beam Impact Test VNotch. 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 Requirement (Note 1) The impact energy shall be: Test specimen in (mm) 10.0 7.5 5.0 2.5 Note : (1) These values are specified for resistance to brittle fracture only. Where additional requirements are specified in project data sheet (Ex. Pipeline Average of three specimens (Note-2) Joules (Min.) 27.0 21.5 18.5 10.0 Minimum single value (Note 1) Joules 22.0 17.5 15.0 8.0 Test specimen width (mm) 10 7.5 5 2.5
materials with arrest properties i.e. a higher upper shelf charpy V energy for resistance against propagating ductile fractures) the same shall be following. (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 as tested as per the requirements of API 11-4 Nineteenth Edition, September 1999. However, the dimensions of the Jig for guided bend test in Fig.9 shall be modified as specified below: Radius of the Plunger A Radius of the die B Width of the die C = = = 2t 3t + 1.6 mm 50.8
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. Note: t = Thickness of specimen
ANNEXURE-2
1.0 ULTRASONIC INSPECTION In addition the radiographic inspection, ultrasonic inspection 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 able to effect the tests without hindering or delaying the pipeline assembly operations. 1..2 Specification For Ultrasonic Testing Procedure Qualification Before work begins, the CONTRACTOR shall present a specification describing the proposed U.T. procedure qualifications. This specification shall state, all the parameters described in API 1104 and the following information: a) b) c) d) e) f) g) h) i) 1.3 Type of U.T. equipment used; Type and dimensions of transducers; Frequency range; Details of calibrations; Coupling medium Inspection technique Record details Reference to the welding procedure where it is intended to adopt the specification Temperature range of the joints to be inspected
Qualification of Ultrasonic Inspection Procedure The ultrasonic inspection procedure shall be approved by the COMPANY. Before inspection begins, the COMPANY may require the qualification test of the ultrasonic inspection procedure. This specification test consists in testing (under normal operating conditions) some COTNRACTOR welds made according to the same production procedure, where there are typical defects in the test intends to defect. This test shall be conducted in the presence of 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 and anyhow the cleaned strip must be at least wide enough to allow one and half skip examination. If during the test, echoes of doubtful origin appear, it shall be necessary to inspect a convenient area o the pipe surface, close to the weld, with a straight beam transducer in order to check whether any manufacturing defects are present which could have interfered with the ultrasonic beam. By way of an example, the equipment shall include but not be limited to the following: a) b) c) d) Ultrasonic equipment and coupling medium Sample sections for calibration of instruments Equipment for cleaning of surface to be examined Rules calibrated in centimetres for exact location of the position of defects
The characteristics of the above listed instruments and equipment shall guarantee: a) b) That the required standards of the inspection procedure, as previously established and approved by the COMPANY, are satisfied 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. 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 instrument: a) shall be pulse echo type, able to generate, receive and display, on the screen a Cathode Ray Tube (CRT), pulse at frequencies between 1 and 6 MHz. The useful part of the CRT screen shall be at least 70 mm wide and at least 50 mm high. Shall have variable amplification, with steps of 1 or 2 dB over a range of at 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 on working 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 stabilising 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.
1.7
Reference Sample Pieces The efficiency of the equipment used, 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.
1.8
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 and 11.4.7.3.
1.10
Qualification of Ultrasonic Testing Operators Before the inspection begins or during the same inspection, 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) b) c) d) e) calibrate the equipment; perform an operational test under production conditions ; Interpret the screen picture; Evaluate the size and location of reflectors 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 Tests Each time that echoes from the weld bead appear during production testing, the instrument amplification shall be altered to coincide with the reference amplifications and the probe shall be moved until maximum response is obtained, paying attention all the time to the probe-tube coupling. If, under these conditions, the height of the defect echo is equal to or greater than that of the reference echo, the defect shall be evaluated according to clause 12.5 of this specification. If the defect has also been detected by the radiographic and/or visual examination, the dimensions shall be judged according to the type of examination which 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 unfavourably 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 centimetres, attached if possible to the probe, for the precise location of the position of welding defects, is recommended. Defect location is effected by measuring the projection distance between the probe output and the reflecting surface. The operators carrying out the tests shall have, besides the probing instrument, tools for cleaning the pipe surface (files, brushes etc) as well as the coupling liquid or paste appropriate for the temperature of the section to be examined.
ANNEXURE-3
RADIOGRAPHY 1.0 SCOPE This annexure covers the radiographic inspection of all types of welded joints of the main pipeline. The welded joints shall include the following: i) Full girth welds on the main line 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 scrapper launching and receiving barrels iv) Terminal piping
2.0
APPLICABLE STANDARDS The specification shall apply in conjunction with the following (all latest edition) : i) ii) iii) API 1104, Standard for welding Pipelines and related facilities ANSI B31.8, Code for Gas Transmission and Distribution Piping Systems ANSI B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols. ASTM E-94, Recommended practice for Radiographic Testing
iv)
v) ASTM E-142, Standard Method for Controlling Quality of Radiographic Testing vi) The American Society of Non-destructive Testing. Recommended Practice No.SNT-TC-1A Supplement A.
3.0 3.1
PROCEDURE The radiographic examination procedure to be adopted shall be submitted by CONTRACTOR as per Exhibit-F. The procedure of radiographic examination shall be qualified to the entire satisfaction of COMPANY prior to use. It shall include but not be limited to the following requirements:
3.2
i) Lead foil intensifying screens, at the rear of the film shall be used for all exposures. ii) iii) Type 2 and 3 films as per ASTM E-94 shall be used 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. Radiographic identification system and documentation for radiographic interpretation reports and their recording system
iv)
3.3
The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior to use. The procedure of radiographic examination shall produce radiographs of sufficient density, clarify and contrast so that defects in the weld or in the pipe adjacent to the weld are clearly discernible. All the girth welds of mainline shall be subjected to 100 % radiographic 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. 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 40 mm. 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. Three copies of each acceptable radiographic procedure (as per Exhibit-F) and three copies of radiographic qualification records shall be supplied to COMPANY. One set of the qualifying radiographs on the job shall be kept by the CONTRACTORs authorized representative to be used as a standard for the quality of production radiographic during the job. The other two sets shall be retained by COMPANY for its permanent record. Three copies of the exposure charts relating to material thickness, kilo voltage, source of film distance and exposure time shall also be made available to COMPANY by the CONTRACTOR. The CONTRACTOR shall, on a daily basis, record for each radiograph (1) Radiographs 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. It must be possible to
3.4
3.5
3.6
3.7
3.8
3.9
relate back to a particular butt weld and welder on piping drawing and pipeline alignment drawing. 3.10 Each days production of processed radiographs shall be properly packaged separately, identified by at least the (1) date (2) radiographic unit (3) job locations (4) starting and ending progress survey stations and (5) shall include original and three copies of the daily radiographic record. The package shall be submitted to the COMPANY daily when possible, but in no event later than noon of the following day. The COTNRACTOR 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. The COTNRACTOR, if found necessary, may modify the procedure of radiographic examination suiting to the local conditions prevailing. This shall, however, be subject to the approval of the Company. COMPANY shall have free access to all the CONTRACTORs work facilities in the field. Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his responsibilities and guarantees. RADIATION SORUCE Radiographic examination shall be carried out using X-radiations, radiographic 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. 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 Radiographic sensitivity required for radiographic inspection shall be at least equivalent to the values in Figure-5. 6.0 6.1 PENETRAMETERS The Image Quality Indicator (Abbreviation: IQI) shall be used for the qualification of the welding procedure and during normal line production. Radiographic sensitivity
3.11
3.12
3.13
3.14
4.0 4.1
4.2
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 sources 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 radio graphed in a single exposure using a source inside the piping, four penetrameters approximately equally spaced around the circumference shall be used. During the procedure qualification, IQI shall be placed both on the source side and on the film side. The sensitivity obtained with IQI on the source side shall not be less than the values shown in Fig.5 of this specification The sensitivity limit may be considered to have been reached when the outline of the IQI, its identification number and the wire of the required diameter show up clearly on the radiograph. The COMPANY may authorise 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 and the CONTRACTORs to show up the identification number and other details of the proposed IQI, which must be visible in the test radiographs. 7.0 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 radio graphed and shall be maintained during radiography. 8.0 8.1 PROTECTION AND CARE OF FILM All unexposed films shall be protected and stored properly as per the requirements of API 1104 standard and ASTM E.94. RE-RADIOGRAPHY The weld joints shall be re-radio graphed in case of unsatisfactory quality of the reradiographs, at the expense of the CONTRACTOR. All the repaired weld joints shall be re-radio graphed 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 When evaluating repair film, radiographers shall compare each section (exposure) of the weld with the original film to assure repair was correctly marked and original defect removed. The COMPANY will review prior to any repair of welds, all the radiographs of welds that contain, according to the CONTRACTORs interpretation, unacceptable
9.0 9.1 9.2
9.3
9.4
defects. The final disposition of all unacceptable welds shall be decided by the COMPANY. 10.0 10.1 10.2 QUALIFICATION OF RADIOGRAPHERS Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and to the full satisfaction of COMPANY. Certification of all 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) ii) iii) iv) v) 10.3 Background and Experience record Training Course Record Technical Examination Record Doctors Report on radiographers Jacque 0-1 acquity eye test Date of qualification
The radiographers shall be required to qualify with each radiographic procedure they use, prior to performing the work assigned to him in accordance with the specification. PRESERVATION OF RADIOGRAPHS The radiographs shall be processed to allow storage of films without any discoloration for at least three years. All the radiographs shall be presented in suitable folders for preservation along with necessary documentation. All the radiographs shall become property of the COMPANY. EQUIPMENT AND ACCESSORIES CONTRACTOR shall make necessary arrangements at his own expense, for providing radiographic equipment, radiographic films and all the accessories for carrying out the radiographic examination for satisfactory and timely completion of the job. For carrying out the mainline radiographic 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 ahs a light source of sufficient intensity and suitably controlled to allow viewing film densities up to 4.0 without damaging the film.
11.0 11.1
11.2 12.0 12.1
12.2
13.0 13.1
RADIATION PROTECTION 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 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. DISPLAY OF SAFETY INSTRUCTIONS 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. ENFORCEMENT OF SAFETY REGULATIONS 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. FIRST AID AND INDUSTRIAL INJURIES CONTRACTOR shall maintain first aid facilities for its employees and those of subcontractors. 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 number shall be posted prominently in CONTRACTORs field office. All critical industrial injuries shall be reported promptly to the COMPANY and a copy of CONTRACTORs report covering each personal injury requiring the attention of physician shall be furnished to the COMPANY. NO EXEMPTION Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from the operation of any other act or rules in force.
13.2 13.3
14.0 14.1
15.0 15.1
16.0 16.1
16.2
16.3
17.0 17.1
EXHIBIT-A Sheet 1 of 3
ELECTRODE QUALIFICATION TEST RECORD A. : : 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) : Tested at (site name) Manufacturers name Date:
B.
All-weld tensile test : Base material used : Pre heat temperature Post welds heat treatment details : Visual examination : Radiographic examination result : Tensile test results :
Identification No. 1. 2.
U.T.S
Yield Point
Elongation
Remarks
EXHIBIT-A Sheet 2 of 3 C. Impact test results Test temperature Type of specimens (Charpy) : : Notch in :
Size of specimens :
Specimen No. 1 2 3 4 5
Impact value
Average
D.
Chemical Analysis Results Electrode size Result Batch No. : :
%C
%S
%P
%Si
%Mn
%Cr
%Ni
%Mo
Other
E.
Fillet weld Test results Welding positions Base materials Size of electrode used Visual Inspection results 1) 2) 3)
: : : : :
EXHIBIT-A Sheet 3 of 3 Macro test Results Fracture test results Remarks F. Other Test results Transverse tensile test In combination with Base material used Position of welding Preheat temperature : ; : : : : : : :
Post weld heat treatment : Radiography Identification No. 2. Guided Bend test Identification No. 1 2 3 4 5 G. H. Any other tests Conclusions : : : Root, Face or Site Bend Remarks : U.T.S. Fracture in Remarks
Position
------------------PREPARED BY (CONTRACTOR)
------------------------REVIEWED BY (CONTRACTOR)
------------------APPROVED BY (OWNER)
EXHIBIT-B Sheet 1 of 1 STRESS RELIEVE HEAT TREATMENT PROCEDURE SPECIFICATION Name of the Heat-treater : Name of the project 1. General Detail: Name of the equipment: Name of the assembly/Part: Drawing No: Material: : 2. Specification reference No. Furnace Details type of heating: Gas/Oil/Elect. res. /Induction Type of Heating Capacity (size) : : :
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) ii) Material test certificates Assembly / Part Drawing. ------------------------REVIEWED BY (CONTRACTOR) ------------------------APPROVEDBY (OWNER) :
------------------PREPARED BY (CONTRACTOR)
EXHIBIT-C Sheet 1 of 3 EXAMPLE OF RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST -------------------------------------------------------------------------------------------------------------Project/Contract Contractor Pipe and fitting material Process Outside diameter Pipe thickness Joint design (Sketch attached) -------------------------------------------------------------------------------------------------------------Make Diameter Current Voltage and type of filler metal --------------------------------------------------------------------------------------------------------------Root Second run Other runs Other electrical a.c/d.c Electrode negative/positive characteristics --------------------------------------------------------------------------------------------------------------Shielding gas Type of mixture Flow Shielding flux Position ---------------------------------------------------------------------------------------------------------------Direction of welding : Root : Vertical up*/Vertical down Second run : Vertical up*/Vertical down Other run : Vertical up*/Vertical down ---------------------------------------------------------------------------------------------------------------Numbers of welder Root Second run Other runs
EXHIBIT-C Sheet 2 of 3 ----------------------------------------------------------------------------------------------Time lapse between commencements of second run and commencement of other runs ----------------------------------------------------------------------------------------------Minimum number of runs before joint allowed to cool Maximum time between commencement and Completion of weld Type of line-up clamp Removal of clamp after run Lowering off after run Cleaning Preheating Minimum temperature C Type of heater to be used Interpass temperature Minimum C Post weld heat treatment Speed of travel Test results State acceptable non-acceptable (with reasons) or give numerical result Non-destructive tests Visual Radiography Maximum C Ambient temperature C
EXHIBIT-C Sheet 3 of 3
Destructive test Transverse tensile Tensile strength (with units) Fracture location Test temperature Macro-examination Fillet weld fracture Hardness survey Type Hardness range Parent metal Heat affected zone Weld Charpy V-notch impact test Specimen location and size Notch location Test temperature Results (with units)
Additional test(s) and results. e.g. chemical analysis, micro-examination, CTOD tests, Bend tests, Nick Break test. The statements in this record are correct. The test joints were prepared, welded and tested in accordance with the requirements of specification.
Contractor Position Date
Inspector Witness by Date
EXHIBIT-D Sheet 1 of 1 Example of record form for welder qualification test Welder test certificate Project/contract contractor Welders name Address Pipe material Pipe thickness Pipe outside diameter Welding process Electrode/wire Root Second run Fill and cap Direction of travel Reason for failure Visual Non-destructive testing Butt joint Fillet weld Number of attempts Comments Accepted date/Time Signed by Contractor Signed by Inspector Current Current Current Voltage Voltage Voltage Root Fill and cap Test no. Date Inspector
Root : Vertical up*/ Vertical down Fill and cap : Vertical up*/ Vertical down
EXHIBIT-E Sheet 1 of 1 WELDERS IDENTIFICATION CARD
Name: Identification: Date of testing: Valid till: Approval of welding: Welding position: Material: Diameter: Diameter range approved: Wall thickness: Thickness range approved: Type of welding consumables: Photograph
Approved by:
Employers signature with seal
EXHIBIT-F Sheet 1 of 1
RADIOGRAPHIC PROCEDURE FOR PIPE WELDING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Location Date of testing Name of supervised contractor Material Dia & thickness Type of weld joint Radiation source(X- ray , iridium) Type of equipment (external / internal) Intensifying screen and material Filter type and placement mask , Diaphragm lead screen etc. adjacent to radiation source or specimen Exposure geometry (source focal spot size, objective to film distance, radiation angle with respect to weld and film). Limit of film coverage Film type and make Exposure condition (ma., KV, time) Processing (time temperature for developed stop bath or rinse, fixation, washing, drying etc.) Density Sensitivity Type of penetrametre Essential wire to be seen on source side Essential wire accepted for film side viewing Signature of CONTRACTOR with seal
Approval of the COMPANY
FIGURE-1 . LOCATION OF SPECIMENS FOR WELD PROCEDURE QUALIFICATION FOR PIPE DIA LESS THAN 12
LEGEND t = Pipe wall Thickness Ls = Weld width after levelling Lc = Length of parallel Edges
FIGURE 3 . HARDNESS TESTING OF WELD JOINTS - SCHEMATIC
NOTCH POSITIONS
DETAIL A
FIG. 4 CHARPY V NOTCH TEST SPECIMEN
FIGURE 5. REQUIRED IQI SENSITIVITY SOURCE SIDE PENETRAMETER
NOTE FOR PRODUCTION RADIOGRAPHY, SENSITIVITY READING BASED ON FILM SIDE PENETRAMETERS ARE TO BE JUDGED AS PER RESULTS FROM THE PROCEDURE QUALIFICATION WITH PENETRAMETER PLACED ON THE SOURCE SIDE
4405-PNMP-TS-0907
WELDING SPECIFICATION CHART
PIPING CLASS:
MAILLINE PIPES API 5L,Gr.X42 -
MATERIAL SPECIFICATION
FITTING FLANGES OTHERS
BASE METAL P NO
1. GROOVE JOINTS BUTT OTHER THAN BUTT SMAW ROOT PASS SMAW GROOVE JOINTS BUTT OTHER THAN BUTT E6010/ E7010G/ E7010P1 ROOT PASS E7018 CONSUMABLE INSERT E6010/ E7018 FILLER PASS E7018/ E70101 SMAW FILLER PASS SMAW
WELDING PROCESS
ROOT PASS
SMAW
FILLER PASS
FILLET / SOCKET JOINTS
WELDING MATERIALS
ROOT PASS
SMAW
FILLER PASS
FILLET / SOCKET JOINTS BACKING RING JOINT PREPARATION GASES GAS COMPOSITION PREHEATING
AS PER ASME B31.8
PURGING PURGING PRE HEAT TEMP HOLDING TEMP
10C MON -
SHIELDING SHIELDING POST HEATING HOLDING TIME MIN HOLDING TIME RATE OF COOLING
CONTINUITY OF WELDING AND PREHEAT REFFER CL 10.2 POST WELD HEAT TRETEMENT RATE OF HEATING METHOD OF COOLING
MECHANICAL PROPERTY REQUIREMENTS CHARPY V NOTCH IMPACT TEST VALUE
MIN
22 J
AVERAGE 0C
27 J
AT TEMPERATURE
CODE OF FABRICATION TECHNICAL NOTES:
ASME B31.8
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREP D
REVWD
APPD
4405-PNMP-TS-0908
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
DOCUMENT NO.
SHEET 1 OF 2
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON _______________________________________________________________________________ Company Name ________________________________________________________ Procedure Qualification Record No. ____________ Date_______________________ WPS No. ______________________________________________________________ Welding Process (es) _____________________________________________________ Types (Manual, Automatic, Semi-Auto) ________________________________________ ________________________________________________________________________ JOINTS Groove Design of Test Coupon (For combination qualification the deposited weld metal thickness shall be recorded for each Filler metal or process weld) ________________________________________________________________________________________ BASE METALS Material Spec.________________________ Type of Grade _______________________ P.No ________ to P.No._______________ Thickness of Test Coupon _____________ Diameter of Test Coupon _____________ Other ___________________________ FILLER METALS Weld Metal Analysis A No. ____________ Size of Filler Metal __________________ Filler Metal E.No. _____________________ SFA Specification __________________ A WS Classification____________________ Other ______________________________ POSITION Position of Groove _____________________ Weld Progression (Uphill, Downhill) _________ Other _______________________________ POSTWELD HEAT TREATMENT Temperature ________________________ Time _____________________________ Other ________________________________
GAS Type of Gas on Gases ________________ Composition of Gas Mixture _____________ Other ________________________________
ELECTRICAL CHARACTERISTICS Current ___________________________ Polarity ____________________________ Amps. __________________________ Tungsten Electrode Size ________________ Other _______________________________ TECHNIQUE Travel Speed ______________________ String or Weave Bead __________________ Oscillation ____________________________ Multipass or Single Pass (per side) __________ Single or Multiple Electrodes __________ Other ______________________________
PREHEAT Preheat Temp. ___________________ Interpass Temp. ____________________
4405-PNMP-TS-0908
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
GUIDED BEND TESTS
Type of Figure No.
Result
TOUGHNESS TESTS Specimen Notch No. Location Notch Type Test Temp. Impact value Lateral Exp. % shear Mils Break Drop weight No Break
FILLET WELD TEST Result Satisfactory: Yes _____No _____Penetration into Parent Metal: Yes_______ No. _____ Marco Results _____________________________________________________ OTHER TESTS Type of Test ___________________________________________________________ Deposit Analysis __________________________________________________________ Other _________________________________________________________________________
Welder's Name _____________ Clock No. _________________Stamp No. _________ Test Conducted by ______________________ Laboratory Test No. __________________ We certified that the statements in this record are correct and test welds were prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code. Date ________________________ Manufacture ______________ By ______________________
(Detail of record of tests are illustrative only and may be molded to conform to the type and number of tests required by codes and specifications).
4405-PNMP-TS-0911
SPECIFICATION FOR REPAIR OF PIPE CORROSION COATING
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
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CONTENTS
1.0 2.0 3.0 4.0
SCOPE MATERIAL AND EQUIPMENT APPLICATION PROCEDURE INSPECTION AND TESTS
1.0
SCOPE This specification covers the minimum requirements for materials and equipment, application procedure and inspection of repair of damaged Polyethylene coating on steel pipes. The repair shall be carried out using repair patch made of radiation cross linked polyolefin backing, coated on the inside with semi-crystalline thermoplastic adhesive and filler mastic.
2.0 2.1
MATERIAL AND EQUIPMENT The repair material shall be as under: a) Repair Patch: radiation cross linked polyolefin with semi-crystalline thermoplastic adhesive (PERP of make Raychem or equivalent). b) Filler Mastic: PERPFILLER of make Raychem or equivalent.
2.2
The material shall not be older than their period of validity at the time of application by the CONTRACTOR. Deteriorated/decomposed materials shall not be used. Materials shall be stored in sheltered storages in the manufacturer's original packing away from direct sunlight and in accordance with manufacturer's instructions. CONTRACTOR shall supply all equipment and manpower 'required for skill full application in the field in accordance with the specification. APPLICATION PROCEDURE The application procedure to be followed for holiday type of damage shall be in accordance with manufacturer's instruction and minimum requirement specified below whichever are the more stringent.
2.3
2.4 3.0 3.1
3.1.1 Preparation Remove coating from damaged area with knife, scraper or power brush. Scrap off the damaged area and adjacent coating to remove oil, grease, rust, dirt and moisture. 3.1.2 Preheating Preheat the exposed bare metal surface to about 60' C and adjacent pipe C0ating to about 40 C with a torch moved back a.'1d forth over the surface. 3.1.3 Application of the Filler Plastic filler shall be cut to size and applied to all exposed .metal surface. The mastic shall be heated and smoothed down with a paint scraper to cover all bare metal in a manner such that all entrapped air is removed
3.1.4 Application of repair tape A patch shall be from the tape in a manner such that it extends 50 mm (2 inch.) beyond the damaged area. The Patch shall be positioned over the damaged area and heated until the temperature sensitive paint on the outside of the patch changes colour. It shall be smoothed down to confirm with the contour of lap, and shall be freed of any air bubbles or wrinkles. 3.2 For cosmetic type of defects such as minor gauging, tearing, and/or scratches which do not indicate holiday during holiday inspection, following procedure shall be adopted.
3.2.1 The defective area shall be roughened to remove loose polyethylene coating, oil, grease, dirt, etc. 3.2.2 This shall be followed by application of patch as detailed in clause 3.1.4. 4.0 4.1 INSPECTION AND TEST A visual inspection shall be carried out for the following:
-
Mastic extrusion on ends of the patch shall be examined. There shall be' no sign of punctures or pinholes or bend failure. The external appearance of the patch shall be smooth, free from dimples, air entrapment or void formation. The entire closure patch shall have changed colour uniformly.
4.2
Holiday inspection The holiday detector used shall be checked and calibrated daily with an accurate D. C. Voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. The entire surface of the repaired section shall be inspected by means of a full circle holiday detector approved by COMPANY set to a D.C. Voltage of at least 25 KV. Inspection of repaired patch shall be conducted only after it has cooled below 50 C.
4.3
All repaired joint shall be approved by the COMPANY.
4405-PNMP-TS-0912
PROJECT & DEVELOPMENT INDIA LIMITED
TECHNICAL SPECIFICATION FOR LOWERING IN
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
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4405-PNMP-TS-0912
DOCUMENT NO.
SHEET 2 OF 4
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 OBJECT EQUIPMENT CAPPING PIPELINE SECTIONS HOLIDAY INSPECTION LOWERING IN FLOODED TRENCH AIR PRESSURIZING PIPELINE SECTIONS
4405-PNMP-TS-0912
DOCUMENT NO.
SHEET 3 OF 4
1.0
OBJECT This specification refers to the lowering-in of the pipelines.
2.0
EQUIPMENT The Contractor shall supply the equipment necessary for lifting, handling and lowering-in the pipelines and for protecting their coating; the: list and the characteristics of the equipment shall be approved by the Engineer. The lifting equipment shall be provided in sufficient quantity and having strength adapted to the characteristics of the pipeline and to the lowering-in order that the pipelines suffer no unusually heavy stresses during the lowering-in operations. The lifting equipment accessories, such as roller cradles, slings, wedges shall be such that no damage is caused to the coating. The dimensions and type shall be approved by the Engineer.
3.0 .
CAPPING PIPELINE SECTIONS Before lowering-in a pipeline section, both ends shall be capped in such a way as to prevent stones and earth from entering the pipeline section during the loweringin operations. The caps shall be of a type approved by the Engineer and shall be removed just before welding.
4.0
Holiday Inspection The holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. The external surface of the pipe section shall be inspected by means of a full circle holiday detector approved by COMPANY set to a DC voltage of at least 25kV. Inspection of the sleeves shall be conducted only after the joint has cooled below 50C (applicable for heat shrink wraparounds).
5.0
LOWERING-IN The Contractor shall carry lowering-in immediately after the Engineer has checked. The quality and the quantity of lifting and handling machines and devices; wide non-abrasive slings or bets shall be used for lowering-in the pipelines. All lowering-in device and padded skids shall be subject to close inspection to ensure that the coating is not damaged before the pipe reaches the bottom of the trench. The good condition of the" coating and its quality or insulation; when the pipeline is constructed with previously coated pipes, not lowered-in directly but placed on skids above or beside the trench, the quality of the coating shall be systematically
4405-PNMP-TS-0912
DOCUMENT NO.
SHEET 4 OF 4
checked and any necessary repairs shall be carried out in conformity with the specification SP 505: External coating of steel pipes The good condition of the trench; when the coated pipeline is to be lowered-in the bottom shall be free of brushes, skids, pipeds, crops, rocks, hard lumps of earth or clay, sticks so that the protective coating shall not be punctured nor abraded. Before lowering in the pipe lines, the: trench shall be padded with a minimum 10 cm compacted padding such as sand or a soft material agreed by the Engineer. Immediately after lowering-in the pipelines the Contractor shall place 20 cm of soft material over them. When a flexion laying of the pipeline is authorized the pipes shall be maintained in the middle of the trench by means of sand bags. 6.0 FLOODED TRENCH When the trench contains water or mud, the trench shall be dried and cleaned before lowering-in any of the pipeline sections. However for certain locations of a limited length, the Contractor may propose for the approval of the Engineer a procedure which without drying out the trench enables the pipeline sections to be normally laid in the bottom of the trench. 7.0 AIR PRESSURIZING PIPELINE SECTIONS As soon as possible after lowering-in the pipeline sections shall be air pressurized at 1 kg/cm2 and the constructed portions of network shall be maintained so pressurized until tightness tests.
4405-PNMP-TS-0913
TECHNICAL SPECIFICATION FOR BACKFILLING THE TRENCH
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
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4405-PNMP-TS-0913 TECHNICAL SPECIFICATION FOR BACKFILLING THE TRENCH DOCUMENT NO SHEET 2 OF 5
CONTENTS
1.0 2.0 3.0 3.1 3.2 3.3 4.0 5.0 6.0 7.0 8.0 OBJECT MATERIAL AND EQUIPMENT BACKFILLING SOFTLAYER ABOVE THE SOFTLAYER TEMPORARY RECONDITIONING PROTECTION OF BACKFILL CLEANING FINAL RESURFACING OBSTACLES SETTLEMENT OF DAMAGES
1.0
OBJECT
This specification refers to the backfilling of the trench after the lowering in of the gas pipelines and to the reconditioning of the surface after the completion of the works. 2.0 MATERIAL AND EQUIPMENT The contractor shall supply the materials and equipment necessary for backfilling the trench and reconditioning the surface in particular. The soft material necessary for protecting the pipe line when they are not present in the backfill. New backfill material to replace that which is considered unsuitable by the engineer. The material necessary for reconditioning the surface. The equipment required for the hauling, backfilling, compacting and reconditioning.
The material and equipment, as well as their conditions of use shall be approved by the engineer 3.0 BACKFILLING The backfilling of the trench shall follow the lowering in of the pipe so that the coating is not exposed to excessive temperature variations and the contractor shall carry out the backfilling operation as soon as the engineer has checked. 3.1. SOFT LAYER The pipelines shall be surrounded with sand or approved soft material on the sides of and above. If agreed by the engineer, the sand will be replaced by a soft layer of stone free earth, coming from the excavated material. Shifting the earth on the worksite shall be forbidden. In all cases, backfilling shall be carried out to the satisfaction of the engineer and so that no damage can be caused to the pipe coating. 3.2. ABOVE THE SOFT LAYER After the soft layer, a waning device as specified in the material specifications shall be placed 0.20 m above the upper tangent of the pipe line. When two pipelines are to be laid in the same trench, the Contractor shall placed two warning device.
Then the backfilling shall be completed with the excavated material by 0.15 m thick layer, each layer being compacted by machines following a procedure approved by the engineer. Unless otherwise mentioned in the special specification, when the trenches are dug in carriage ways, the backfilling is completed with a 0.20 m thick layer of lean concrete. 3.3. TEMPORARY RECONDITIONING
3.3.1. Normal Unless otherwise mentioned in the special conditions and/or specifications, the contractor shall provide a temporary reconditioning, which must be carried out immediately after backfilling and compacting, by reusing digging materials: after compacting, the top of the backfill shall be 5 cm above the ground level. 4.0 PROTECTION OF BACKFILL One steep slope where flowing water is likely to run through the trench, thus wasting out the backfill, the contractor shall install the necessary protection as directed by the Engineer. 5.0 CLEANING The Contractor shall clean the worksite as the work filling proceeds. Cleaning shall be carried out by mean of light equipment, so as to minimise public inconvenience.
6.0
FINAL RESURFACING Unless otherwise mentioned in the special conditions and/or special specifications, and as soon as possible after the backfilling of the trench, the Contractor shall proceed to resurface the land occupied for the execution of the works, the same as the original, in accordance with the relevant authorities requirements. He shall clear the ground of equipment, pipe crops and debris all kinds. He shall store to an identical condition, the accesses, fencing, ditches, banks, supporting walls and generally all structures destroyed damaged or moved for the execution of the works.
7.0
OBSTACLES The condition for executing the backfilling and the reconditioning of the surface where an obstacle is involved are defined in the specification Obstacle crossings and special passages.
8.0
SETTELEMENT OF DAMAGES The Contractor shall responsible for any damage caused to various public or private structures, arising from the works or access to the site, the occupation of land for installing Contractors stockyard, offices and workshops. The Contractor shall make settlement with the owner or relevant authorities and get from them a letter of discharge as formal acknowledgement that the reconditioning and repair have been properly carried out; a copy of this letter of discharge shall be given to the Engineer. The document does not release the Contractor from his responsibilities concerning work which may prove to be necessary up until the final acceptance of the installations.
4405-PNMP-TS-0915
SPECIFICATION FOR HYDROSTATIC TESTING [ONSHORE PIPELINES]
18.02.09
18.02.09 EFF DATE
ISSUED PURPOSE
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APPD
SPECIFICATION FOR HYDROSTATIC TESTING (ON SHORE PIPELINES)
TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 SCOPE REFERENCE CODES, STANDARDS AND SPECIFICATIONS GENERAL HYDROSTATIC TEST PROCEDURE MANUAL TEST PRESSURE EQUIPMENT AND INSTRUMENTATION PROCEDURES ACCEPTANCE TERMINATION TEST REPORT MEASUREMENTS CALCULATIONS PRECAUTIONS DURING THE TEST PRESERVATION OF PIPELINE
FIGURES FIG.1 TABLES TABLE 1 DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL EXPANSION FACTOR. WATER COMPRESSIBILITY FACTOR VS PRESSURE AND TEMPERATURE.
1.0 1.1
SCOPE This specification covers the minimum requirements of supply, works and operations to be performed by CONTRACTOR for hydrostatic testing of cross-country steel pipelines transporting hydrocarbons in liquid or gaseous phase under high pressure. This specification does not cover the requirements of drying / pre-commissioning of the tested pipelines. This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between Consultant/Owner and CONTRACTOR. Unless specified otherwise, all sections of this specification shall apply to all specifications referred in this specification. REFERENCE CODES, STANDARDS AND SPECIFICATIONS Reference has been made in this specification to the latest edition/revision of the following codes, standards and specifications. a) b) c) d) ANSI B 31.8 ANSI B 31.4 API RP 1110 : : : Gas Transmission and Distribution Piping Systems. Liquid Petroleum Transportation Piping Systems. Pressure Testing of Liquid Petroleum Pipelines.
1.2
2.0 2.1
ASME Sec.VIII Boiler & Pressure Vessels Code Div.1
2.2
In case of conflict between the requirements of this specification and that of the above referred codes, standards, and specifications, the requirements of this specification shall govern. For the purpose of this specification the following definitions shall hold: the words 'Shall' and 'Must' are mandatory; the words 'Should', 'May', and 'Will' are non-mandatory, advisory or recommended.
2.3
3.0 3.1
GENERAL Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall be performed in accordance with approved Hydrostatic Test Diagrams for each test section. The maximum length of each test section shall not exceed 25 kms. For pipeline sections which in Consultant / Owner's opinion, once installed would require an inordinate amount of effort for repair in case of a leak, a provisional pretest shall be conducted. However, after installation, such pre-tested sections shall be tested again along with the entire pipeline.
3.2
3.3
Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all welds have been accepted and the pipeline has been laid and backfilled according to the specifications. Hydrostatic test shall include those sections which have been previously tested, viz. Rail/road crossings, major water crossings including test on banks and in place after installation, and scraper traps at the terminals. CONTRACTOR shall perform all works required for hydrostatic testing after obtaining prior written approval from the Consultant/Owner. The pipeline shall be tested in accordance with the requirements of the latest edition of ANSI B 31.8 or ANSI B 32.4, as applicable, and requirements laid down in this specification. HYDROSTATIC TEST PROCEDURE MANUAL CONTRACTOR shall prepare for Consultant/Owner's approval a hydrostatic test procedure manual. The procedure shall strictly comply with the requirements of this specification and shall be submitted to Consultant/OWNER for approval well in advance. The procedure manual shall include all temporary materials and equipment, but not be limited to the following items:
3.4
4.0
a)
For the systems to be tested, a diagram indicating all fittings, vents, valves, temporary connections, relevant elevations and ratings. The diagram shall also indicate injection locations and intake and discharge lines. Estimated amount of test water, water sources, including required concentration of corrosion inhibitors and additives, procedure for inhibitor injection and control of concentration. Filling and flushing procedures, including a complete description of all proposed equipment and instruments (including spares), their location and set-up. The type and sequence of pigs and the pig tracking system for cleaning and removal of air pockets. Pig inspection procedures, including procedure to be followed in case the caliper pig indicates damage. Procedures for leveling and stabilization after filling and for pressurization and to allow for temperature stabilization. Pressure testing procedure including a complete description of all proposed equipment and instruments (including spares), their location and set-up, and proposed system for observation and recording of data during the pressure test. Procedure for detection and location of leaks. Procedure for dewatering the pipeline section(s) after testing, including a complete description of all proposed equipment and instruments (including spares), their location and set-up, the type and sequence of pigs and the pig tracking system along with the pig specifications.
b)
c)
d)
e)
f)
g) h)
i) 5.0 5.1
Forms for recording the test data. TEST DURATION AND PRESSURE The duration of hydrostatic test shall be minimum 24 hours after stabilization and the test pressure shall be as indicated in the approved hydrostatic test diagram. Unless specified otherwise in the CONTRACT, the maximum test pressure shall not be higher than the one resulting in a hoop stress corresponding to 90% of SMYS of pipe material based on the minimum wall thickness in the test section and minimum test pressure shall not be lower than the one resulting in a hoop stress corresponding to 85% of SMYS of pipe material based on the minimum wall thickness in the test section. EQUIPMENT AND INSTRUMENTATION The CONTRACTOR shall furnish all necessary equipment for performing the work as stated in cleaning, flushing, filling, leveling, stabilizing, testing and dewatering procedures. This shall include, but not be limited to, the following equipment and instruments:
5.2
6.0
a)
Pigs for filling, cleaning and gauging: Cleaning pigs with spring loaded steel wire brushes except for internal coated pipe. In this case pigs to be provided with nylon / polyurethane brushes. Four cup batching pigs; Caliper pigs with gauge plate diameter equal to 95% of the heavy wall pipe in the pipe sections.
The CONTRACTOR shall provide a sufficient number of pigs, including spares. b) Fill pumps: The CONTRACTOR shall determine the type and number of fill pumps in order to guarantee the following: differential head 20% greater than the maximum required. flow rate: minimum 400 m3/h maximum 1000 m3/h
If a single pump is used, a standby unit must be available. c) Variable speed positive displacement pumps equipped with a stroke counter to pressurize the line with a known stroke and capable of exceeding the maximum test pressure by at least 20 bar.
d)
Two positive displacement meters to measure the volume of water used for filling the line. These meters shall be provided with a calibration certificate not older than one month. Portable tanks of sufficient size to provide a continuous supply of water to the pump during pressurizing. Bourdon pressure gauges of suitable pressure range and accuracy. Dead weight testers with an accuracy of 0.01 bar measuring in increments of 0.05 bar provided with a calibration certificate not older than one month. Two 48 hours recording pressure gauges with charts and ink gauges tested with dead weight tester prior to use. These shall be installed at the test heads. Pressure recording charts. Two temperature recorders for fill water. Thermocouples for measuring the pipe wall temperature.
e)
f) g)
h)
i) j) k) l)
Two laboratory thermometers 0C to 60C range, accuracy 0.1 degrees to be used in thermo wells. Means to measure the volume of water necessary to drop the line pressure by 0.5 bar (container on scales or graduated cylinder). Injection facilities to inject additives into the test medium in the required proportions. Communication equipment suitable for a continuous connection between the beginning and the end of the test section and with the inspection team along the line, in accordance with the requirements of Local Authorities. The temporary scraper traps shall be installed according to the testing sections fixed in the test procedure manual. Proper piping and valving arrangements shall be available to allow launching and receiving of each pig independently. The test heads shall be sized in conformity with ASME specification Section VIII, Division 2 with particular reference to Appendices 4 and 5.
m)
n) o)
p)
q)
Thermocouples for measuring the temperature of the pipe wall shall be installed on the pipeline to be tested: 1 thermocouple at about 500 m distance from the pumping head. 1 thermocouple every 2500 m of the pipe. 1 thermocouple at about 500 m distance from the terminal head.
Thermocouples shall be attached on the external surface of the pipe after removal of external coating and shall be adequately protected and Consultant/Owner's coating instruction shall be followed. 7.0 7.1 PROCEDURES Equipment and/or parts which need not or must not be subjected to the test pressures, or which must not be tested with water, must be disconnected or separated from the pipeline to be tested. If the difference of minimum and maximum atmospheric temperature should cause thermal instability on the pipe section directly exposed to atmospheric condition, the scraper traps and above ground pipeline shall be properly protected. The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz. aerial lengths on piers, suspension bridges, etc., which sections shall be tested separately. The test medium shall be soft non-aggressive water furnished by the CONTRACTOR. The water to be used shall be filtered, shall not be contaminated, and free from sand or silt. CONTRACTOR shall submit laboratory test reports of water used for testing. The possible use of sea water shall be subjected to its degree of cleanness, the possibility of obtaining a pre-determined salinity neutralization and the use of corrosion inhibitors, this at the sole discretion of Consultant/Owner. CONTRACTOR shall provide Consultant/Owner approved corrosion inhibitors, oxygen scavengers and bactericides to be added to the test water. The CONTRACTOR shall furnish and install all temporary piping which may be necessary to connect from source of water to its pumps and manifolds/tank ages. Before filling operation the CONTRACTOR shall clean the pipeline by air driven pigs provided with spring loaded brushes and chisels to remove all mill scale rust/sand from the internal of pipe sections. The finishing touch shall be executed with pigs provided with air jet holes or nozzles to keep the internal dust in turbulence ahead of the pigs. The number of pig runs is depending upon the cleaning results and shall be determined by the Consultant/Owner at site. After cleaning the pipeline by using air and accepted by Consultant/OWNER, the whole length of pipeline shall be filled with water without inhibitor. Air vents shall be kept closed at the start of filling to allow pressure to build up in front of the pig train. Cleaning and four cup pigs shall be passed to remove mud, dirt, debris and any other extraneous material. The cleaning grade shall be evaluated by the Consultant/Owner. It shall be considered acceptable when no relevant extraneous material are found in front of the last four cup pig. A caliper pig shall be launched using inhibited water in order to check possible out-of-roundness along the pipeline. The results of the caliper pig run shall be analyzed to evaluate the internal status of the pipeline. Thermal Stabilization After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the highest section, the thermal stabilization can be started.
7.2
7.3
7.4
7.5
7.6
Thermal equilibrium between the pipeline and environment shall be checked through the thermocouples installed on the pipeline. Temperature readings shall be made at 4 hours-intervals. Thermal stabilization shall be considered to have been achieved when a difference not higher than 1C is attained between the average values of the last two readings. Thermal stabilization completion shall be approved by Consultant/Owner. 7.7 Pressurization The pressurization shall be performed in the presence of Consultant/Owner at the moderate and constant rate not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel with the dead weight tester. Volume required to reach the test pressure shall be recorded periodically throughout the pressurization as each 5 bar increments up to 80% of test pressure as recorded by the dead weight tester; each 2 bar increment between 80% to 90% of test pressure as recorded by the dead weight tester; each 0.2 bar increments between 90% of the test pressure to full test pressure as recorded by the dead weight tester.
The pressurizing shall be cycled according to the following sequence: a) Pressurize to 50% of test pressure, hold pressure for 1 hour. b) Drop pressure to static head of test section at test head. c) Pressurize to 75% of test pressure, hold pressure for 1 hour. d) Drop pressure to static head of test section at the test head. e) Pressurize to test pressure. During the pressurization to each test pressure, two tests shall be carried out for the calculation of air volume in the pipeline under test. In case, during the hold pressure periods indicated above, a decrease in pressure is observed, the above operations shall not be repeated more than twice, after which the line shall not be considered capable of test, until the CONTRACTOR has isolated and eliminated the cause for the lack of water tightness. 7.8 Air Volume Calculation In order to check the presence of air in the pipeline, two separate consecutive pressure lowering of 0.5 bar shall be carried out.
For calculation of air in the pipeline the second pressure lowering shall be used, and the relevant drained water shall be accurately measured (V1). This amount measured shall be compared to the theoretical amount (Vp) corresponding to the pressure lowering that has been carried out, by using the procedure outlined in clause 12.1 of this specification. If no air is present in the length under test: V1 ----- = 1 Vp In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e. 1.06). If the air found in the pipeline is within the above established tolerance, then the pressurizing can continue. If the ratio V1/Vp exceeds 1.06, the hydrostatic testing cannot go on and additional pig passages shall be performed to remove the air pockets. The test shall be repeated as per the above procedure until above estimated tolerances are satisfied. The pressurizing can then continue, to reach the value of the test pressure. 7.9 Testing After the section has been pressurized and the air volume test has given acceptable results the test pressure shall be held for a minimum of 24 hours after stabilization. After temperature and pressure has stabilized, the injection pump shall be disconnected and all connections at the test heads shall be checked for leakage. The pressure recorders shall then be started with the charts in a real time orientation for continuous recording throughout the test. During the testing period the following measurements shall be recorded/reported: every one hour pressure measurements from dead weight testers. every two hours the ambient temperature and the pipe temperature at the thermocouples. All data shall be recorded on appropriate forms attached to the hydrostatic test procedure manual. Care shall be taken that the maximum test pressures are not exceeded. Bleed-off water shall be accurately measured and recorded. ACCEPTANCE
8.0
8.1
The hydrostatic test shall be considered as positive if pressure has kept a constant value throughout the test duration, except for change due to temperature effects. Such change shall evaluated as described under Clause 12.2 of this specification. The pressure change value as a function of temperature change shall be algebraically added to the pressure value as read on the meters. The pressure value thus adjusted shall be compared with the initial value and the test shall be considered as acceptable if the difference is less than or equal to 0.3 bar. In case of doubt the testing period shall be extended by 24 hours.
8.2
If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shall determine by search the location of leakage or failure. All leaks and failures within the pipe wall or weld seam shall be repaired by replacement of entire joint or joints in which leakage or failure occurs. In those cases where leaks occur in circumferential welds the method of repair shall be determined by the Consultant/Owner. CONTRACTOR shall comply with instructions of the Consultant/Owner whether to replace a section of the line pipe that includes the line leak or whether to repair the circumferential weld. This repair should, however, meet the requirements of ' Welding Specification for Onshore Pipelines (Doc no - 4241PNMP-TS-0919).Where failures occur in pipeline field bends, bends shall be replaced with same degree of bends. After completion of repairs, the hydrostatic test shall be repeated in full, as per this specification. The cost of repairs or replacements, followed by refilling and repressurizing the line, due to poor workmanship, shall be borne by the CONTRACTOR. In the event of leaks or failures resulting from faulty Consultant/Owner furnished materials, CONTRACTOR shall be reimbursed for furnishing all labour, equipment, materials, except those materials furnished by the Consultant/Owner, and transportation necessary to repair and repressurize the section of the pipeline to the pressure at the time of recognition of leak or line failure. CONTGRACTOR shall be entitled for compensation as per the provisions of the CONTGRACT. All work of reinstalling line pipe, to replace failures, shall be done in accordance with the relevant specifications included in the CONTRACT.
8.3
8.4
CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations designated by the Consultant/Owner. All cracks and splits resulting from failures shall be coated with an application of grease to preserve the characteristics of failures from corrosion. Joint of failed pipes shall be marked with paint, with a tag indicating failure details, date and location of failure and pressure at which failure occurred. TERMINATION After the positive results of testing and all the data have been gathered, the test shall be terminated upon written approval given by the Consultant/Owner. The pipeline shall be slowly depressurized at a moderate and constant rate as instructed by Consultant/Owner.
9.0
9.1
CONTRACTOR shall dewater the tested line as per the following requirement after test acceptance. The dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed air. The detailed dewatering procedure shall be developed by the CONTRACTOR in such a way as to provide adequate control of pigs during dewatering. Pigs and equipment required for dewatering the line shall be furnished by CONTRACTOR and shall be approved in advance by the Consultant/OWNER. Four cup pigs shall first be passed through the line to displace the water. Foam pigs shall then be passed in order to complete the line dewatering. CONTRACTOR shall use a number of foam pigs each in different colours/numbered for this purpose. The line shall be considered dewatered when a negligible amount of water is flushed out by the last foam pig and approval is given by the Consultant/Owner.
9.2
During dewatering, care shall be taken to properly dispose the discharging water in order to avoid pollution, damages to fields under cultivation and/or existing structures and interference with the traffic. Upon completion of the testing and dewatering operation, any provisional traps for pigs and all other temporary installation relating to the test shall be removed. Subsequently the individual sections of the line already tested shall be joined in accordance with the requirements of relevant specifications issued for the purpose. TEST REPORT A complete report signed by CONTRACTOR and the Consultant/Owner shall be submitted upon completion of the hydrostatic test for each test section. This report shall contain as a minimum: the cleaning, flushing, filling and testing procedures used; schematic layout of cleaning, filling and testing facilities; instruments calibration certificate; a profile of the pipeline that shows the test sites, all instrument and injection connections; pipe filling logs and records; additive specification, required concentration and additive injection records; pig specifications; pig inspection records including photographs of the damages; records of gauging pig survey and photographs;
9.3
10.0
Pressurization and stabilization records; pressure and temperature recording charts with appropriate information inscribed thereon; temperature data along the pipeline; dead weight tester logs and recording; air volume calculations;
- pressure change due to temperature change calculations. 11.0 11.1 environmental data; depressurization logs and records; dewatering procedure and schematic layout of relevant facilities; dewatering logs and records; records and photograph of all leaks.
MEASUREMENTS Water Amount Measurement The water volume added to the section to be tested shall be measured during the filling stage through a positive displacement meter (a turbine meter may also be used). In the calculation, as per clause 12.1 of this specification, use shall be made of the geometrical volume of the section in question. The water amount that has been let into the section shall be measured during the pressurization stages through positive displacement meters or turbine meters.
11.2 Pressure Measurement Pressure shall be measured with a dead weight tester that shall permit readings of at least 0.05 bar. During the test the pressure shall be recorded by means of a recording pressure gauge featuring the following specifications: Accuracy Recording : 0.1% of the full-scale value : continuous on tape or disk, graph width 100mm.
Feed
20mm/h for tape diagrams, 7.5/h for disk diagrams.
Recording range: to be such as to record pressure between 50% and 90% of the diagram width. The recording pressure gauge shall be checked by means of dead weight test at the beginning, during and at the end of the hydrostatic test. 11.3 a) Temperature Measurements Water temperature shall be taken at every 4 hours through the thermocouples that have been installed along the section under test on the pipe wall. Further, the temperature measurement shall be taken: during the filling operation during the thermal stabilization stage during the hydrostatic test
The thermocouples' sensitivity shall enable temperature readings with accuracy of 0.2C. b) Water temperature shall also be measured on the pump delivery by means of a recording thermometer throughout the filling stage. The recording thermometer shall feature the following characteristics: Accuracy : 1% of the scale range Scale : - 10 to + 40C
Recording : Continuous on tape or disk, diagram width 100 mm. Feed c) : 20mm/h for tape diagrams, 7.5/h for disk diagrams.
Ground temperature shall be taken by measuring pipe temperature at the thermocouples prior to starting the filling operation. Environmental temperature shall be recorded from the beginning of pressurization to the end of the test by means of a recording thermometer featuring the following characteristics: Accuracy : 1% of the scale range Scale : 0C to + 60C
d)
Recording : Continuous on tape or disk, diagram width 100 mm.
Feed 12.0 12.1 CALCULATIONS
: 20mm/h for tape diagrams, 7.5/h for disk diagrams.
The theoretical water amount that is necessary for filling the section to be tested shall be obtained from the geometrical volume of the section considering the pipe tolerances. The theoretical water amount that is necessary for pressurizing the section shall be calculated by means of the following formula: ri (0.884 ----+ A) x 10-6x Vt x P x K t
Vp =
Where: Vp = computed water amount required to raise by P the pressure in the section to the tested (m3). Vt =geometrical volume of the section (m3) P=pressure rise (bar) ri =nominal inner radius of the pipe (mm) t =nominal pipe thickness (mm) A =isothermal compressibility value for water at the pressurization temperature in the P range (bar -1) x 106. (Refer water compressibility factor vs pressure and temperature chart). K =a dimensionless coefficient that is equal to a value of 1.02 for longitudinally welded pipe. 12.2 The pressure change due to a water temperature change shall be calculated through the following formula: B P = ------------------- T 0.884 ri -- + A t Where. P = pressure change resulting from a temperature change(bar).
T = algebraic difference between water temperature at the beginning of the test and water temperature as measured at the end of the test (C). B = value of the difference between the thermal expansion of water at the pressure and temperature as measured at the end of the test and that of steel (C-1) x 106. (Refer Table 1) A = Isothermal compressibility value of water as estimated at the pressure and temperature values obtained at the end of test (bar-1) x 106 (Refer Figure 1).
ri t
= nominal inner radius of the pipe (mm) = nominal pipe thickness (mm).
13.0
PRECAUTIONS DURING THE TEST In addition to all that has been expressly described in the procedures for carrying out the tests, the following additional requirements shall be complied with:
13.1
Provision shall be made for the installation of no-admittance signs to unauthorized personnel from the roads to the R.O.W. Signs stating "PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed where the pipeline is uncovered, and particularly where the provisional traps and stations are located. Such areas shall be suitably fenced in such a way as to prevent access of unauthorized personnel. No unauthorized personnel shall be closer than 40 m to the pipeline or equipment under test. Provisional scraper traps shall be installed in compliance with methods and suitable locations so that their rupture cannot cause any injuries to the personnel or third parties.
13.2
13.3
13.4 The test station shall be placed in such a location as to prevent it from being affected by a catastrophic failure in the test head. 13.5 Once dewatering is over, the sectionalizing valves and other valve assemblies tested previously shall be installed at locations shown in the drawings and in accordance with the procedures contained in the relevant specifications. All thermocouples installed in the pipeline shall be removed and damaged corrosion coating shall be repaired using Consultant/Owner approved materials and procedure. PRESERVATION OF PIPELINE
14.0
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration, CONTRACTOR shall completely fill the pipeline with water, with sufficient quantity of corrosion inhibitors depending upon quality of water and the period of conservation, at a pressure to be agreed upon with the Consultant/Owner at a later stage. CONTRACTOR shall obtain necessary approval from the Consultant/Owner of the procedure and the type and quantity of the inhibitors used before commencement of the works.
1 2 3 4 5 6 7 8 Bar -------------------------------------------------------------------981 -98.62 -79.89 -61.81 -44.34 -27.47 -11.14 + 4.66 +19.98 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 -95.55 -92.15 -88.74 -85.32 -81.90 -78.47 -75.03 -71.60 -68.16 -64.72 -61.28 -57.84 -54.40 -50.96 -47.53 -44.10 -40.67 -37.24 -33.83 -30.42 -27.02 -76.94 -73.68 -70.40 -67.12 -63.84 -60.55 -57.25 -53.96 -50.66 -47.35 -44.05 -40.74 -37.44 -34.13 -30.83 -27.53 -24.23 -20.94 -17.65 -14.37 -11.09 -58.99 -55.86 -52.72 -49.58 -46.43 -43.27 -40.10 -36.94 -33.77 -30.60 -27.43 -24.26 -21.08 -17.90 -14.73 -11.56 - 8.40 - 5.23 - 2.06 + 1.09 + 4.25 -41.65 -38.64 -35.63 -32.62 -29.60 -26.58 -23.54 -20.51 -17.47 -14.43 -11.38 - 8.34 - 5.29 - 2.25 + 0.80 + 3.85 + 6.89 + 9.94 +12.98 +16.01 +19.04 -24.89 -22.01 -19.14 -16.24 -13.36 -10.46 - 7.56 - 4.65 - 1.73 + 1.18 + 4.10 + 7.02 + 9.95 +12.87 +15.79 +18.72 +21.64 +24.56 +27.48 +30.40 +33.31 - 8.67 - 5.92 - 3.16 - 0.41 + 2.36 + 5.15 + 7.92 +10.70 +13.50 +16.29 +19.08 +21.88 +24.68 +27.49 +30.29 +33.10 +35.90 +38.70 +41.51 +44.30 +47.10 + 7.02 + 9.65 +12.29 +14.93 +17.57 +20.23 +22.89 +25.55 +28.23 +30.90 +33.58 +36.26 +38.94 +41.63 +44.31 +47.00 +49.69 +52.37 +55.06 +57.75 +60.43 +22.23 +24.74 +27.26 +29.78 +32.31 +34.85 +37.39 +39.94 +42.50 +45.05 +47.61 +50.18 +52.75 +53.32 +57.89 +60.46 +63.04 +65.62 +68.19 +70.77 +73.34 ---
220 -23.63 - 7.82 + 7.40 +22.06 +36.22 +49.90 +63.12 +75.90 -----------------------------------------------------------------
TABLE 1
: DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL EXPANSION FACTOR (C-1). 10-6
Continuation C 1 2 3 4 5 6 7 8 Bar --------------------------------------------------------------------230 240 250 260 270 280 290 300 -20.24 -16.87 -13.50 -10.14 - 6.80 - 3.48 - 0.17 + 3.13 - 4.56 - 1.30 + 1.94 + 5.17 + 8.39 +11.60 +14.80 +17.98 +10.54 +13.67 +16.79 +19.90 +23.00 +26.11 +29.19 +32.27 +25.08 +28.10 +31.11 +34.12 +37.11 +40.09 +43.07 +46.03 +39.13 +42.03 +44.92 +47.81 +50.69 +53.56 +56.43 +59.29 +52.69 +55.48 +58.26 +61.04 +63.80 +66.57 +69.33 +72.08 +65.80 +68.48 +71.15 +73.81 +76.48 +79.14 +81.78 +84.83 +78.48 +81.05 +83.61 +86.81 +88.73 +91.29 +93.83 +96.38
-----------------------------------------------------------------------
TABLE 1:
DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL EXPANSION FACTOR (C-1) . 10-6
C
9 10 11 12 13 14 15 Bar ---------------------------------------------------------------------981 +34.82 +49.22 + 63.20 + 76.78 + 89.99 +102.83 +115.34 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 +36.97 +39.36 +41.76 +44.18 +46.60 +49.02 +51.44 +53.88 +56.32 +58.77 +61.21 +63.67 +66.12 +68.58 +71.05 +73.51 +75.97 +78.44 +80.91 +51.26 +53.55 +55.84 +58.14 +60.45 +62.76 +65.08 +67.40 +69.73 +72.07 +74.41 +76.74 +79.09 +81.45 +83.80 +86.15 +88.51 +90.87 +93.23 + 65.15 + 67.33 + 69.51 + 71.70 + 73.90 + 76.10 + 78.32 + 80.53 + 82.75 + 84.98 + 87.22 + 89.45 + 91.69 + 93.93 + 96.18 + 18.43 +100.68 +102.94 +105.19 + 78.64 + 80.71 + 82.79 + 84.87 + 86.96 + 89.07 + 91.17 + 93.29 + 95.41 + 97.53 + 99.66 +101.79 +103.93 +106.07 +108.21 +110.36 +112.51 +114.66 +116.82 + 91.75 + 93.72 + 95.70 + 97.68 + 99.68 +102.67 +103.68 +105.69 +107.70 +109.73 +111.75 +113.79 +115.83 +117.87 +119.90 +121.96 +124.01 +126.06 +128.12 +104.51 +106.39 +108.26 +110.14 +112.04 +113.93 +115.84 +117.76 +119.67 +121.59 +123.52 +125.46 +127.39 +129.34 +131.20 +133.74 +135.19 +137.15 +139.11 +116.93 +118.71 +120.49 +122.28 +124.07 +125.88 +127.69 +129.50 +131.32 +133.15 +134.98 +136.82 +138.67 +140.51 +142.37 +144.22 +146.08 +147.94 +149.81 -
200 +83.37 +95.59 +107.45 +118.97 +130.17 +141.07 +151.68 --------------------------------------------------------------------
TABLE 1 : DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL EXPANSION FACTOR (C-1). 10-6
Continuation C 9 10 11 12 13 14 15
Bar -----------------------------------------------------------------------210 + 85.84 97.95 +109.71 +121.13 +132.24 +143.03 +153.55 220 230 240 250 260 270 280 290 + 83.30 + 90.67 + 93.22 + 95.69 + 98.14 +100.60 +103.05 +105.50 +100.31 +102.67 +105.03 +107.39 +109.74 +112.10 +114.44 +116.79 +111.97 +114.23 +116.48 +118.74 +121.00 +123.25 +125.50 +127.75 +123.29 +124.45 +127.60 +129.76 +131.92 +134.08 +136.24 +138.39 +134.29 +136.36 +138.42 +140.48 +142.54 +144.61 +146.67 +148.73 +144.99 +146.96 +148.93 +150.90 152.87 +154.84 +156.84 +158.78 +155.42 +157.30 +159.18 +161.05 +162.93 +164.81 +166.69 +168.57
300 +107.94 +119.13 +130.00 +140.54 +150.79 +160.75 +170.45 --------------------------------------------------------------------------
TABLE 1:
DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL EXPANSION FACTOR (C-1). 10-6
Continuation C 16 17 18 19 20 21 22 23 Bar ---------------------------------------------------------------------------.981 +127.52 +139.41 +151.00 +162.31 +173.37 +184.18 +194.75 +205.08 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 +129.02 +130.71 +132.40 +134.10 +135.80 +137.51 +139.22 +140.95 +142.67 +144.42 +146.15 +147.90 +149.65 +151.40 +153.16 +154.93 +156.69 +158.47 +160.24 +140.83 +142.42 +144.02 +145.62 +147.24 +148.86 +150.49 +152.11 +153.75 +155.40 +157.04 +158.70 +160.36 +162.03 +163.70 +165.37 +167.05 +168.73 +170.42 +152.36 +153.85 +155.35 +156.87 +158.39 +159.92 +161.46 +163.00 +164.56 +166.11 +167.66 +169.24 +170.81 +172.39 +173.98 +175.56 +177.15 +178.75 +180.35 +163.58 +165.00 +166.42 +167.85 +169.29 +170.73 +172.18 +173.64 +175.10 +176.58 +178.05 +179.54 +181.02 +182.51 +184.00 +185.51 +187.02 +188.53 +190.05 +174.56 +175.90 +177.23 +178.58 +179.93 +181.29 +182.66 +184.03 +185.41 +186.80 +188.20 +189.59 +191.00 +192.41 +193.82 +195.24 +196.66 +198.09 +199.52 +183.30 +186.55 +187.80 +189.07 +190.34 +191.62 +192.91 +194.20 +195.50 +196.80 +198.12 +199.44 +200.75 +202.09 +203.42 +204.76 +206.10 +207.45 +208.80 +195.79 +196.96 +198.14 +199.33 +200.52 +201.72 +202.93 +204.14 +205.36 +206.59 +207.82 +209.06 +210.31 +211.56 +212.81 +214.08 +215.34 +216.61 +217.89 +206.07 +207.16 +208.26 +209.37 +210.49 +211.61 +212.74 +213.88 +215.03 +216.17 +217.33 +218.49 +219.66 +220.84 +222.02 +223.20 +224.39 +225.58 +226.79
200 +162.01 +172.10 +181.95 +191.57 +200.97 +210.16 +219.17 +227.99 ----------------------------------------------------------------------------
TABLE 1:
Continuation C 16 17 18 19 20 21 22 23 Bar --------------------------------------------------------------------------210 +163.80 +177.80 +183.55 +193.09 +202.40 +211.53 +220.46 +229.20 220 230 240 250 260 270 280 290 +165.58 +167.36 +169.16 +170.94 +172.73 +174.53 +176.32 +178.11 +175.49 +177.19 +178.89 +180.59 +182.30 +184.00 +185.70 +187.42 +185.16 +186.78 +188.39 +190.01 +191.63 +193.25 +194.88 +196.50 +194.62 +196.14 +197.68 +199.21 +200.75 +202.29 +203.83 +205.37 +203.85 +205.30 +206.75 +208.20 +209.66 +211.12 +212.59 +214.05 +212.89 +214.26 +215.63 +217.00 +218.40 +219.77 +221.16 +222.54 +221.74 +223.04 +224.33 +225.63 +226.93 +228.24 +229.55 +230.86 +230.41 +231.63 +232.85 +234.08 +235.31 +236.54 +237.77 +239.01
300 +179.90 +189.13 +198.13 +206.92 +215.51 +223.93 +232.18 +240.26 ----------------------------------------------------------------------------
TABLE 1:
Continuation C 24 25 26 27 28 29 30 Bar ---------------------------------------------------------------------.981 +215.22 +215.14 +234.88 +244.41 +253.79 +263.00 +272.03 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 +216.13 +217.15 +218.18 +219.21 +220.25 +221.30 +222.35 +223.42 +224.48 +225.56 +226.64 +227.73 +228.82 +229.92 +231.03 +232.14 +233.26 +234.38 +235.51 +225.99 +226.94 +227.88 +228.85 +229.82 +230.79 +231.78 +232.77 +233.76 +234.76 +235.78 +236.79 +237.81 +238.84 +239.87 +240.91 +241.96 +243.01 +244.06 +235.66 +236.53 +237.41 +238.30 +239.20 +240.11 +241.02 +241.94 +242.87 +243.79 +244.73 +245.68 +246.63 +247.59 +248.55 +249.52 +250.49 +251.47 +252.46 +245.13 +245.94 +246.75 +247.58 +248.40 +249.24 +250.08 +250.93 +251.79 +252.66 +253.53 +254.40 +255.28 +256.18 +257.07 +257.97 +258.88 +259.79 +260.71 +254.44 +255.18 +255.93 +256.69 +257.45 +258.22 +258.99 +259.78 +260.57 +261.36 +262.17 +262.98 +263.69 +264.62 +265.44 +266.28 +267.12 +267.97 +268.82 +264.59 +264.27 +264.95 +265.64 +266.33 +267.04 +267.75 +248.47 +269.19 +269.92 +270.77 +271.41 +272.16 +272.92 +273.69 +274.46 +275.23 +276.01 +276.80 +272.57 +273.18 +273.80 +274.42 +275.07 +275.70 +276.35 +277.01 +277.66 +278.33 +279.01 +279.69 +280.38 +281.08 +281.78 +282.49 +283.20 +283.92 +284.64 --
200 +236.64 +245.12 +253.45 +261.63 +269.67 +277.59 +285.37 ----------------------------------------------------------------------
TABLE 1:
Continuation C 24 25 26 27 28 29 30 Bar -------------------------------------------------------------------------210 +237.77 +246.18 +254.45 +262.50 +270.54 +278.39 +286.11 220 230 240 250 260 270 280 290 +238.91 +240.06 +241.21 +242.36 +243.52 +244.68 +245.84 +247.01 +247.26 +248.33 +249.41 +250.49 +251.58 +252.66 +253.76 +254.86 +255.45 +256.46 +257.46 +258.48 +259.49 +260.52 +261.54 +262.57 +263.49 +264.43 +265.37 +266.31 +267.27 +268.23 +269.18 +270.15 +271.40 +272.28 +273.16 +274.04 +274.92 +275.82 +276.71 +277.61 +279.19 +280.00 +280.82 +281.63 +282.46 +283.29 +284.12 +284.95 +286.85 +287.59 +288.35 +289.11 +289.86 +290.64 +291.40 +292.18 -------
300 +248.18 +255.96 +263.60 +271.11 +278.51 +285.79 +292.95 --------------------------------------------------------------------
TABLE 1:
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 1 OF 11
TECHNICAL SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPELINES)
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREPD
REVWD
APPD
TECHNICAL SPECIFICATION FOR FIELD JOINT COATING ( ONSHORE PIPELINES )
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 2 OF 11
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
SCOPE REFERENCE DOCUMENTS MATERIAL AND EQUIPMENT APPLICATION PROCEDURE INSPECTION TESTING REPAIRS DOCUMENTATION
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 3 OF 11
1.0 1.1
SCOPE This specification covers the minimum requirements of materials, equipment and installation of field joint coating of pipelines by corrosion protection tapes or heat shrink wraparounds/sleeves. This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between COMPANY and CONTRACTOR. Unless specified otherwise, all sections of this specification shall apply to all specifications referred in this specification.
2.0 2.1
REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition of the following standards and specifications: a) b) c) DIN-30672 SIS-055900 SSPC-SPI : Corrosion Protection Tapes and Heat Shrinkable Sleeves. : Pictorial Surface Preparation Standard for Painting Steel Surfaces. : Steel Structure Painting Council.
2.2 3.0 3.1
In case of conflict between the requirements of this specification and that of above referred documents, the requirements of this specification shall govern. MATERIAL AND EQUIPMENT General
3.1.1 CONTRACTOR shall supply joint coating materials, all equipment and manpower required for a skilful and adequate application of coating in the field in accordance with the specifications. 3.1.2 CONTRACTOR shall submit and demonstrate to COMPANY proposed materials and work procedures for applying field coating and repair procedures for same. These proposed procedures and all materials, equipment and tools used in the work shall be subject to Companys approval. 3.2 Field Joint Corrosion Coating Material
3.2.1 Field joint corrosion coating materials shall be suitable for a minimum in service temperature of +500C. The field joint corrosion coating material shall be of the types as stated herein after. Properties of the joint coating material shall meet the requirements of clause 3.2.4 given below. 3.2.1.1Heat Shrinkable Wraparound Sleeve Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 4 OF 11
high shear strength thermoplastic / co-polymer hot melt adhesive: The joint coating system may consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing shall be coated with thermo chrome paint which will change color when the desired heat during shrinking is attained. The wraparound sleeve shall be supplied in pre-cut sizes to suit the pipe diameter and the requirements of overlap. 3.2.1.2 Field applied pipe wrap Field applied pipe wrap shall consist of PVC / Polyethylene backing with a uniform thickness of self adhesive bituminous rubber compound and shall be of the type that can be applied without use of any primer. Thickness of the wraparound sleeve shall be as per Manufacturers standard. Properties of the cold applied pipe wrap shall meet the requirements of para 3.2.3 of this specification. Cold applied pipe wraps shall be supplied in pre-cut sizes complying the requirements of this specification, to enable easy application during laying operations. 3.2.2 The thickness of various field joint coating materials shall be such that an average thickens of 2.0 mm is guaranteed on the complete finished field joint coating. The minimum permissible thickness at the apex of weld seam shall be 1.6 mm. Properties of joint corrosion coating material
3.2.3
3.2.3.1 Properties of the backing and the as-applied joint corrosion coating shall be as follows: SI. NO. i) ii) iii) iv) v) vi) PROPERTIES Tensile Strength at +250C Ultimate Elongation % at +250C Dielectric withstand KV with 1000 Volt / Sec. Water absorption 24 hour , at +250C Volume Resistivity at +250C Resistance to Thermal Aging at +1000C UNITS N/mm2 % kv % Ohm - cm % REQURIMENT 12 250 30 0.05 1015 Change in Elongation, 25% TEST METHOD ASTM D - 638 DIN 30672 ASTM D-149 OR DIN 30672 ASTM D-570 ASTM D-257 DIN 30672
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 5 OF 11
3.2.3:2 Properties of Joint Coating System (As applied) PROPERTIES Resistance to impact at +250C Class C, 30 Blows Resistance to impact at + 250C, Class C WIDTH At +250C - With Metal Surface - With Mill coating - At layer Overlap At +500C - With Metal Surface - With Mill coating - At layer Overlap iii) iv) v) Cathodic Disbondment (after 30 days) Test method A, at + 600C Resistance to Indention, at + 500C Lap Shear Strength at + 500C, Between Wrapping & Metal Surface and Mill Coating. mm mm N/ cm2 3 2 3 30 0.6 Remaining Thickness 5 ASTM G-42 DIN 30672 DIN 30672 15 8 15 UNITS N / mm DIN 30672 REQURIMENT No Holidays TEST METHOD DIN 30672
SI. NO i) ii)
3.2.4 Contractor shall obtain prior approval from Company regarding the manufacturer of the joint coating material. Complete technical details along with test certificates complying with the requirements of clause 3.2.4 shall be submitted to Company for this purpose. Only Company approved manufacturers shall supply the materials."
3.3
The materials shall not be older than their period of validity at the time of application by CONTRACTOR. Deteriorated/decomposed material shall be disposed of and replaced by CONTRACTOR at his own expense.
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 6 OF 11
CONTRACTOR shall ensure that the coating materials supplied by him are properly packed and clearly marked with the following: 3.4 Manufacturer's name Material qualification Batch number Date of manufacturing and date of expiry.
CONTRACTOR shall ensure that the Manufacturer has carried out all quality control tests on each batch and manufacturer shall provide test certificates to certify that the supplied materials meet the manufacturer's specifications as indicated in the purchase order and as approved by COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall be submitted by CONTRACTOR to COMPANY prior to application. COMPANY reserves the right to have the materials tested by an independent laboratory. Materials shall be stored in sheltered storage in the manufacturer's original packing and away from direct sunlight and In accordance with manufacturer's instructions. CONTRACTOR shall provide and maintain mobile facilities which contain all necessary equipment and its spares for cleaning, coating, repairs, inspection and tests. CONTRACTOR shall furnish sufficient number of the following equipment and the required spares as a minimum for inspection and test purposes for each crew: Fully automatic full circle adjustable holiday detector with a visible and audible signal system for inspection of coatings. Thickness gauge for measuring thickness.
3.5 3.6 3.7
4.0 4.1
APPLICATION PROCEDURE General
4.1.1 The application procedure shall be in accordance with manufacturer's instruction and the minimum requirements specified below whichever are the most stringent and shall be demonstrated to and approved by the COMPANY. Manufacturer's expert shall supervise the application and shall be available at site upon request during qualification of application procedure and during construction at CONTRACTORS cost.
4.1.2 Operators for coating application shall be given necessary instructions and training before start of work, by the CONTRACTOR. To verify and qualify the application
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 7 OF 11
procedures, all coating applied during the qualification test, shall be removed for destructive testing until the requirements stated in sections 'Inspection' and 'Testing', of this specification are met. 4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose. Solvent cleaning procedure according to SSPC-SPI shall be followed: 4.1.4 Prior to surface cleaning the surfaces shall be completely dry. Surface shall be sand blasted to a finish equivalent to SA 2 of Swedish Standard SIS-O55900. 4.1.5 The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall be thoroughly cleaned as specified. 4.1.6 All steel joint surfaces shall be thoroughly examined before the application of the coating in order to ensure .the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter. All these substances shall be removed before coating, to the procedures herein described. 4.1.7 Protection coating shall be applied on the joints immediately after the completion of cleaning operation. 4.2 Application of Heat Shrink Wraparound/Sleeves In addition to the general requirements stated above, following shall be taken into account: 4.2.1 The wraparound sleeve shall be of a size such that a minimum overlap of 50 mm is ensured (after shrinking) on both sides of the yard applied corrosion coating of pipes. In case the HDD is being carried out by without casing then Dirax heat shrinkable steekes shall be used for joint coating. In the cases where carrier pipe is installed by direct boring / jacking / HDD, the overlap on the mill coating for the leading edges of the joints shall be minimum 200 mm. When this extra overlap is achieved by providing an additional patch of heat shrink tape / wrap around, it shall be applied in such a manner that the square edge of the patch on the joint coating is in the direction opposite to the direction of boring/jacking / HDD 4.2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated with a torch moved back and forth over the surface. The minimum pre-heat temperature shall be as recommended by manufacturer and shall be checked by means of pyrometer. To check this, approved temperature indicators shall be used. Temperature indicating crayons shall not be used. 4.2.3 The wraparound sleeve shall be entirely wrapped around the pipe positioning the closure patch off to one side of the pipe in 10 or 2 O'clock position, with the edge of the undergoing layer facing upward and an overlap of min. 100 mm.
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 8 OF 11
4.2.4 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner such that all entrapped air is removed using gloved hands and hand rollers. The complete shrinking of the entire sleeves shall be obtained without undue heating of existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. A thermo chrome paint shall be applied on the closure patch to indicate the sufficient heat/temperature has been obtained. The installed sleeve shall not be disturbed until the adhesive has solidified. 4.3 Application Procedure for Corrosion Protection Tapes In addition to general requirements stated before, following shall be taken care of: 4.3.1 4.3.2 Cold applied joint protection tapes shall be of the type which can be applied by spirally wrapping on the pipe. Immediately after the completion of surface preparation, the approved primer shall be applied as per manufacturer's recommendations. Any dirt on the primed surface shall be removed. If the primer is damaged, the damaged area shall be cleaned and Reprimed.
4.3.3 Approximately 100 mm of tape interleaving paper shall be peeled back and tape shall be applied with the adhesive side to the pipe. Whilst continuously removing the interleaving paper, the tape shall be spirally applied to provide a minimum of 55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air pockets and also continuously smooth out as the wrapping proceeds. The wrapping shall start and finish to give a minimum of 50 mm overlap on to the adjoining yard applied coating. Outer wrap shall also be applied in similar method. In the cases where carrier pipe is installed by direct boring/jacking, 'the overlap on the mill coating for the leading edges of the joints shall be minimum 200 mm. The direction of spiral wrapping in these cases shall be such that the square edge of the wrapping with the joint coating is in the direction opposite to the direction of boring / jacking. 5.0 5.1 INSPECTION A visual inspection shall be carried out for the following: Mastic extrusion on either ends of the sleeve shall be examined (Applicable shrink wraparounds). There shall be no sign of punctures or pinholes or bend failure. The external appearance of the sleeve shall be smooth, free of dimples, air entrapment or void formation. Weld bead profile shall be visible though the sleeve The entire closure patch shall have changed colour uniformly (applicable for heat shrink wraparounds).
5.2
Holiday Inspection The holiday detector used shall be checked and calibrated daily with an accurate DC Voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected.
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 9 OF 11
The entire surface of the joint section shall be inspected by means of a full circle holiday detector approved by COMPANY set to a DC voltage of at least 25kV. Inspection of the sleeves shall be conducted only after the joint has cooled below 50C (applicable for heat shrink wraparounds). 5.3 6.0 No field joint shall be covered or lowered in the trench until it has been approved by the COMPANY. TESTING
6.1
COMPANY reserves the right to remove and test one out of every 50 joint coatings or one joint coating out of every day's production whichever is stringent. CONTRACTOR shall provide all assistance in removing and testing of field joint coatings.
6.2
The required peel strength shall meet the requirements of clause 3.2.4.2(ii) as applicable for 250C or 500C whichever is feasible. This test shall be conducted between wrapping & metal and mill coating & between layers at overlap with joint coating (wherever applicable). After removal of strip the bulk of adhesive shall remain adhered to the pipe showing no bare metal, otherwise, test shall be considered failed
6.3
If the sleeve taken away for test does not meet the requirements of clause 6.2, the adjacent two sleeves shall also be removed and inspected. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve every twenty five until Company's Representative is satisfied. The test rate can then be reduced as per clause 6.1
If either or both of the adjacent two sleeves do not meet the requirements of clause 6.2, the field coating shall be stopped (Refer clause 7.0).
6.4
COMPANY Representative reserve the right of 100% removal of sleeves if he is not convinced that the requirements of clause 6.2 are achieved.
6.5
Coating thickness shall be checked by non-destructive methods for each field joint.
7.0
REPAIRS
7.1
If a field joint is detected to be unacceptable after testing as per section 6.0 of this
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DOCUMENT NO.
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Specification the CONTRACTOR shall, at his own cost:
determine the cause of the faulty results of the field coating.
mobilise the expert of manufacturer, if required.
Test to the complete satisfaction of the COMPANY, already completed field coatings
stop field coating until remedial measures are taken against the causes of such faults, to the entire satisfaction of the COMPANY.
7.2
CONTRACTOR shall replace all joint coating found or expected to be unacceptable as per section 6.0 of this specification.
7.3
CONTRACTOR shall, at his own cost repair all areas where the coating has been removed for testing by the COMPANY.
7.4
After the coating work on welded joints, fittings and repairs to the coating have been completed the coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline.
7.5
COMPANY shall be entitled to check the coating on buried pipelines or parts of pipelines with equipment such as the "Pearson Meter" and the resistance meter. If coating defects are established, the CONTRACTOR shall be responsible for excavation at such points, repairing the coating, spark testing and backfilling the excavations without extra charge.
8.0
DOCUMENTATION
8.1
Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the Manufacturer and, material:
4405-PNMP-TS-0916
DOCUMENT NO.
SHEET 11 OF 11
Complete descriptive technical catalogs describing the materials offered along with samples of corrosion coating materials, its properties and application instruction as applicable specifically to the project. Test certificates and results of previously conducted tests, for all properties listed in clause 3.2.4 of this specification.
ii.
iii.
Reference list of previous supplies, in last 5 years, of the similar material indicating the project details such, as diameter, quantity, operating temperature, year of supply, project name, contact person and feed back on performance
Once the Company's approval has been given,' any change in material or Manufacturer shall be notified to Company, whose approval in writing. of all changes shill be obtained before the materials are manufactured.
4405-PNMP-TS-0919
STANDARD SPECIFICATION FOR INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
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PREP D
REVWD
APPD
CONTENTS
1.0 2.0 3.0 4.0
SCOPE INSPECTION FLUSHING TESTING
1.
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.
INSPECTION During various stages and after completion of fabrication and erection, the piping system shall be inspected by the Engineer-Incharge to ensure that Proper piping material has been used. Piping has been erected as per drawings and instructions of Engineer-InCharge. All supports have been installed correctly. Test preparations mentioned in this specification have been carried out.
3.
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 valve, orifice plates, rotameters, safety valves and other instruments like thermowells which may interfere with flushing shall not be included in flushing circuit. The screens / meshes shall be removed from all permanent strainers before flushing. Screens / meshes shall be reinstalled after flushing but before testing. During flushing temporary strainers shall be retained. cleaned and reinstalled after flushing but before testing. These shall be removed,
In case 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-Incharge. 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, aris8ing 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 in exhibit F. 4.0 4.1 TESTING Extent of Testing With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be tested irrespective of whether or not they have been pressure tested prior to site welding of fabrication. To facilitate the testing of piping systems, vessels and other equipments may be included in the system with the prior approval of Engineer-In-Charge if the test pressure specified is equal to or less than that for the vessels and other equipments. Pumps, compressors and other rotary equipments shall not be subjected to field test pressure. Lines which are directly open to atmosphere such as vents, drains, safety valves discharge need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines shall be tested by continuous flow of fluid to eliminate the possibility of blockade. However, such lines if provided with block valve shall be pressure tested upto the first block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working pressure of the valve. Test pressure applied to valves shall not be greater than the manufacturers recommendation nor less than 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 / or 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 Preparations 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. 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 as close as possible to the lowest point 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 pressurise upstream side of valve. Replace the valve by a temporary spool and reinstall the valve after testing. Provide blind on valve flanges and test the upstream and downstream of the line separately and remove the blind after testing. At these flanges, temporary gaskets shall be provided during testing and shall be replaced by permanent gaskets subsequently. For check valves in lines 1-1/2and below flapper or seat shall be removed during testing (if possible). After completion of testing the flapper / seat shall be refitted. Gas lines when hydrostatically tested shall be provided with additional temporary supports during testing as directed by the Engineer-In-Charge. Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of the fluid would overload the support. Retaining pins for spring supports shall be removed only after testing is completed and test fluid is completely drained. When testing any piping system, air or steam of approximately 2 Kg/cmg 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 SS piping shall be 15-20 ppm.
4.3.2 Test Pressure The hydrostatic / pneumatic test pressure shall be as follows:-The selection of the piping system for one individual test shall be based on the following: Test pressure should be 1.4 times the design pressure and duration shall be 4 hrs. 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 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 Procedures
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 valved 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 four 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. 4.5 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 tests 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 as given in exhibit F.
4405-PNMP-TS-0920
TECHNICAL SPECIFICATION FOR PURGING AND COMMISSIONING THE NETWORK
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREP D
REVWD
APPD
CONTENTS
1.0 2.0 3.0 4.0 5.0 5.1 5.2 5.3 6.0 7.0 8.0 9.0 OBJECT MATERIALS AND EQUIPMENT WORK SCHEDULE SAFETY PRECAUTIONS PURGING GENERAL PIPELINES ACCESSORIES PROCEDURE TO BE FOLLOWED FOR NITROGEN PURGING REPAIRS PERFORMANCE DEFECTS CERTIFICATE OF COMPLETION
1.0
OBJECT This specification refers to the preparatory and execution operations for purging and commissioning a gas distribution network.
2.0
MATERIAL AND EQUIPMENT The Contractor shall supply all materials and equipment necessary for: purging the pipelines from Nitrogen supervising the purging operations checking that the performances of the accessories conform to the contract adjusting the accessories commissioning the works
The contractor shall also supply and have ready on site: The replacement materials such as valve operation indicators, plastic caps for casting etc which may be damaged during the start-up operations. If such materials are taken from the spare parts to be supplied by the Contractor, they shall be immediately replaced. Safety equipment such as fire extinguishers, gas masks, gas analysers etc to ensure labour and public safety. M/s GAIL GAS will supply the gas free of charge, at the required pressure and flow. 3.0 WORK SCHEDULE The contractor shall draw-up and submit a purging schedule to the Engineers approval, in the conditions specified in the specification Documents drawn up by the Contractor. This schedule shall specify: The portion of network to be purged The characteristics of the works to be purged The operation sequence and the description of the equipment intended to be used The staff intended to be mobilized including the necessary specialists and technicians of the manufacturers of the materials, if necessary.
4.0
SAFETY PRECAUTIONS The contractor may not proceed to the purging until safeguards have been placed around the installation and works, where they are needed in application of the safety regulations. The contractor shall be required to satisfy any public regulations. He shall, where necessary, obtain permission from the concerned authorities before beginning any
operations, and he shall take all the necessary precautions to ensure safety of persons and properties during the purging operations: these precautions must be made known to all persons concerned and if necessary shall be publicised. 5.0 5.1 PURGING GENERAL The purging operations include: purging the pipelines from Nitrogen checking the performances of the accessories adjusting the accessories All these operations shall be performed under the supervision of the Engineer and in the presence of representatives of the Company. The Contractor shall give a 3 (three) days notice. They shall not start unless the network is thoroughly completed and all test certificates regarding the concerned works have been signed and the purging schedule is approved by the Engineer. 5.2 PIPELINES The purging operations for pipelines include: 5.3 making accessible the purging devices of the portion of network to be started up installing the vent pipes and/or torches on to the purging devices Purging from air to gas the network in such a way that the eventual ring mains be purged before the branch lines Removing the vent pipes and/or torches, when the networks is filled with gas Backfilling the eventual excavations at purging device locations
ACCESSORIES The contractor shall check the performance of the accessories in accordance with the manufacturers instructions. These checks shall include in particular: The manual opening and closing of all valves The electrical check and all insulating flanges are in good working condition The inspection of good working condition and adjustment of checking and safety devices
6.0
PROCEDURES TO BE FOLLOWED FOR NITROGEN PURGING: Following procedure shall be followed to purge the gas pipeline with nitrogen
First of all the pipe line network shall be blown off with compressed air to blow off all the material, sand and dust particles etc Now the pipeline network shall be purged with compressed nitrogen (containing maximum 1000 ppm O2) at around 5 kg/cm2g pressure .The operation is repeated three times till the oxygen content in the purge gas outlet reduces to 2% .When the entire network has been purged, it is kept in isolation and kept under a positive nitrogen pressure. Now the pipeline network is ready to be charged with natural gas 7.0 REPAIRS The contractor shall replace as quickly as possible any parts and devices supplied by him and proving to be defective. 8.0 PERFORMANCE DEFECTS If the performance of the accessories does not meet the contract requirements, the contractor shall take any necessary steps to remedy the situation as soon as possible, even by installing any additional device which might prove necessary. 9.0 CERTIFICATE OF COMPLETION When the followings are completed in accordance with the contract provisions: the network is completely constructed and all accessory installations are installed and tested, including telecommunication cables, if any the network is purged from Nitrogen, it proves to be tight the accessory performances prove to conform to the contract the accessories are adjusted to the operation conditions all connections are made , all marker plates and signs are installed the site test certificates regarding the works have been signed by the Engineer The factory test certificates regarding the materials have been handed over to the engineer by the contractor. The technical records have been handed over to the engineer by the contractor
The engineer shall deliver the certificate of completion regarding the network or concerned portion of network to the contractor.
4405-PNMP-TS-0921
SPECIFICATION FOR TECHNICAL RECORDS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREP D
REVWD
APPD
4405-PNMP-TS-0921
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 OBJECT COMPOSITION OF TECHNICAL RECORDS TECHNICAL DOCUMENTS AS-BULT DOCUMENTS DRAWING-UP OF TECHNICAL RECORDS HANDING OVER OF TECHNICAL RECORDS
4405-PNMP-TS-0921
1.0
OBJECT These specification relate to the preparation, drawing-up, presentation by the Contractor, his Sub-contractors and suppliers and handling over to the Engineer of the documents which constitute the technical records of the pipelines, stations and accessory works constructed by the Contractor
2.0
COMPOSITION OF TECHNICIAL RECORDS The technical records shall be composed of: the technical documents which shall be drawn up progressively by the Contractor as the execution of the works proceeds, kept continually up to date transmitted to the Engineer at his request and returned to the Contractor for correction or complement if any the as-built documents which shall be in conformity with the construction of all the works and handed over to the Engineer at the date of issued of the certificate of completion.
3.0
TECHNICAL DOCUMENTS These documents shall include: Construction drawings The welders qualification certificates The reports on the weld inspection The welding reports The sectioning of the pipeline for the testing The reports on tests carried out on site, in application of the regulation texts, on pipeline stations and accessory works, as well as ,if need be, the reports drawn up the representation of the Authority in charge of the inspection of the tests. AS-BUILT DOCUMENTS These documents include in particular: the map of the final route of the pipeline the as-built drawings at the scale mentioned in the Special Specifications and recording: - the depth of the pipeline - The characteristics of the pipes and the limits for changes in characteristics
3.0
4405-PNMP-TS-0921
5.0
The position and size of pipeline equipment such as valves, casing, insulating joints, and currents tapes, vents, telecommunication cables, etc. the position of the markers the plans which are conform to the construction of the stations and accessory works and other equipment, bearing the exact list of plans and diagrams of the cathodic protection installations the starting-up reports of the works (pipeline, station, accessory works, cathodic protection) the measurements and operation tests the final discharge obtained by the Contractor from owners, operators, municipal authorities after the restoration of the ground surface inventory of equipment supplied by the Company to the Contractor for the construction of the works the welding records the radiographic exposures of welds.
DRAWING-UP OF TECHNICAL RECORDS The drawing-up of the documents of technical records with regard to the preparation, presentation, form and size, procedure for transmission and approval shall be submitted to the rules defined in the specification Documents drawn-up by the Contractor.
6.0
HANDING OVER OF TECHNICAL RECORDS The technical records (one set of soft copy and 4 set of hard copies) shall be handed over to the Engineer at the date of the certification of completion.
4405-PNMP-TS-0922
TECHNICAL SPECIFICATION FOR PREPARATION OF THE STEEL PIPES
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREPD
REVWD
APPD
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 6.1 6.2 7.0 7.1 7.2 7.3 7.4 8.0 9.0 10.0
OBJECT MATERIALS AND EQUIPMENT CHECKING THE PIPES INTERNAL CLEANING CLEANING THE ENDS CUTS AND BEVELS STRAIGHT PIPES MITERED PIPES DIRECTION: DIVERSION FLEXION FIELD COLD BENDING FACTORY ELBOWS MITERED BENDS TEES CHECKING OF INSIDE SECTION REJECTED PIPES
1.0
OBJECT This specification refers to the checking, cleaning, cutting and bending of steel pipes before welding.
2.0
MATERIALS AND EQUIPMENT The contractor shall supply the materials, equipment, machines and accessories necessary for the preparation of the pipes. The bending machines shall be fitted with the proper equipment and in particular internal mandrels, if required by the pipe diameter and wall thickness. The wearing parts shall be in good condition and renewed as soon as required. Any machine producing defective bends shall be immediately replaced. The electric tools such as brushes and grinders shall be fitted with the regulation safety devices.
3.0
CHECKING THE PIPES The contractor shall examine each pipe before its preparation. Any pipe showing defects, such as distortions, flattened ends, bumps, notches, grooves, scratches, corrosion pits, shall be put aside for examination by the engineer who may order the rejection, repair or cutting of the pipe in order to eliminate the defect.
4.0
INTERNAL CLEANING Before assembling the pipes shall be cleaned internally by running a pipe brush. All operations shall be conducted in such a way as to prevent any foreign matters from entering into the pipelines.
5.0
CLEANING THE ENDS Before proceeding to the line-up of the pipes and immediately before executing the root bead, each pipe-end shall be cleaned, down to the metal by a rotary wire brush, file or grinder, if necessary. This cleaning shall be carried out on the bevel and land as well as on the inside and outside walls of the pipe and over a distance of at least five (5) centimetres.
6.0
CUTS AND BEVELS The cuts and bevels shall be made, either with cutting torch and bevelling machine, or with any other machine approved by the Engineer.
6.1
STRAIGHT PIPES Hand cutting by torch is forbidden. The plane of the cut shall be perpendicular to the axis of the pipe. The rough-cut pipe ends shall be ground so that bevels and lands meet the bevelled pipes specifications.
6.2
MITERED PIPES For the mitered pipes, the plane of the cut is not perpendicular to the axis of the pipe: hand cutting by torch is allowed. The pipe shall be bevelled by grinding.
7.0 7.1
DIRECTION DIVERSION FLEXION There is no flexion permitted during laying of basic grid steel pipes. In all other cases, the diversion of the pipes in the field shall be carried out by cold bending or by using factory elbows and miter bends.
7.2
FIELD COLD BENDING The bending of coated pipes in the field shall only be carried out with the approval of the Engineer, all coating repairs being the responsibility of the contractor. The bending shall be so done as to avoid any flattering or buckling. Any flattered or buckled pipe shall be rejected. On longitudinally welded pipe, bending shall be so done that the seam is 15(fifteen) from the neutral axis of the bend. When several welded pipes are to be bent together, no bending shall be done on the tie-in-weld. Out- of roundness measured across the maximum and minimum cross section at the centre of the bend shall not exceed 2.5% of the pipe O.D.
7.3
FACTORY ELBOWS The contractor may use factory elbows or segments cut there from, provided that the arc length measured along the crotch is at least 25.4 mm on pipes 50 mm in diameter and larger.
7.4
MITERED BENDS Mitered bends are not permitted on pipelines intended to operate at 30 percent or more of the specified minimum yield limit elastic strength. Deflections caused by misalignment up to 3 degrees are not considered as miters. Mitered bends are permitted for pipelines intended to operate at less than 30 percent of the specified minimum yield strength. In that case, the contractor may use miter bends for deflections angles equal to or less than 12.5. The minimum distance between miters, measured at the crotch, shall not be less than one pipe diameter.
8.0
TEES Whenever the pipelines are to be internally cleaned by scrappers or spheres, the contractor shall weld flush with the branch of the tees the necessary number of guiding bar in order to avoid any blockage.
9.0
CHECKING OF INSIDE SECTION A Pipeline to be cleaned by scrapers, after the internal cleaning of foreign materials, the inside section of each straight and bent pipe shall be checked by running a gauge made of two steel plates and approved by the Engineer. The distance between the plates shall be equal to twice the nominal diameter of the pipe to be checked. The diameter of the plates will be given in the special specifications. Any pipe, whether bent or not, which does not allow the free run of the gauge shall be rejected.
10.0
REJECTED PIPES The rejected pipes shall be marked REJECTED in red paint. These pipes shall be immediately removed from the work site by the contractor, hauled and stocked at a depot approved by the Engineer.
4405-PNMP-TS-0926
DOCUMENT NO SHEET 1 OF3
TECHNICAL NOTES FOR GASKETS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
Issued PURPOSE
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APPD
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4405-PNMP-TS-0926
1. The process of manufacture, dimensions and tolerances not specified in requisition shall be in accordance with the requirements of the manufacturers standards. 2. All gaskets shall conform to the codes/standards and specifications given in the requisition. Deviation(s), if any, shall be clearly highlighted in the quotation. 3. a. Test reports shall be supplied for all mandatory tests for CAF gaskets as per the standards specified in the requisition. Chemical composition of RTJ gaskets shall also be furnished in the form of test reports on samples.
b.
4. Full face gaskets shall have bolt holes punched out. 5. Manufacturers test certificate for filler material and spiral material shall be given as per the relevant material specifications for spiral wound gaskets. 6. Asbestos filler for spiral wound gaskets shall not have any colour or dye. 7. a. All spiral wound gaskets shall be supplied with C.S. outer centring ring except for gasket material description suffixed as (540+) or (CRYO). In these cases outer-centring ring shall be of SS 304/316. Inner compression ring of S.S. shall be provided for the following, unless mentioned otherwise. (i) (ii) (iii) For gasket sizes 26 and above. For gasket rating 900# and above. For gasket material description suffixed as (425+) or (CRYO) or (540+).
b.
8. Hardness of metallic RTJ gaskets shall not exceed the values specified below : RING GASKET MATERIAL Soft Iron Low C.S. 5 Cr. Mo Type 304, 316, 347 Type 304L, 316L MAXIMUM HARDNESS (BHN) 90 120 130 140 120
9. Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

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4405-PNMP-TS-0926
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. 11. All items shall be inspected and approved by OWNER/CONSULTANT Inspector or any other agency authorised by OWNER/CONSULTANT. 12. Any additional requirements specified in the requisition, shall be fully complied with.
Notes: 1. Non-metallic ring gaskets as per ANSI B16.21 shall match flanges to ANSI B16.5 upto 24 and flanges to API 605 above 24 unless specifically asked for otherwise. 2. Spiral wound gasket as per API 601 shall match flanges to ANSI B16.5 upto 24 and flanges to API 605 above 24 unless specifically asked for otherwise.
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4405-PNMP-TS-0927
TECHNICAL NOTES FOR BOLTS AND NUTS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
Issued PURPOSE
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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 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. Threads shall be unified (UNC for 1 dia and 8UN for > 1 dia) as per ANSI B.1.1 with class 2A fit for studs, M/c bolts and jack screws and class 2B fit for nuts. Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall be in accordance with the requirement of table F2 of Annexure-F of ANSI B 16.5. The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot forged process and stamped as per respective- material Specification. Heads of jack screws and m/c bolts shall be heavy hexagonal type. Jack screw end Shall be rounded. 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. All items shall be inspected and approved (stage wise) by OWNERS inspector or any other agency authorized by OWNER. The heat treatment for stud bolts & nuts shall be as per code unless mentioned Otherwise. All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed Condition unless specified otherwise in the material specification.
2.
4.
5.
6.
7.
8.
9.
10.
11.
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12. 13.
Any additional requirement specified in the requisition shall be fully complied with. 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 "CRYO". For S.S. nuts and bolts minimum impact energy absorption shall be Joules and test temperature shall be -196 deg. C unless mentioned otherwise in code. For other materials impact energy and test shall be as per respective code. Bolts/nuts of material of construction B7M/2HM shall be 100% Hardness tested as per supplementary requirement S3 of ASTM A 193. When specified as galvanized, the studs, m/c bolts and nuts shall be hot dip zinc Coated in accordance with requirements of class C of ASTM A 153.
14.
15.
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4405-PNMP-TS-0928
TECHNICAL SPECIFICATION FOR VALVES
0 REV
18.02.09 18.02.09 REV DATE EFF DATE
Issued PURPOSE
AS
AKS
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PREPD
REVWD
APPD
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TECHNICAL SPECIFICATION FOR VALVE
1.0 SCOPE .............................................................................................................................................. 3 1.1 1.2 DEFINITIONS................................................................................................................................... 3 APPLICABLE CODES AND STANDARDS.................................................................................. 3
2.0 DESIGN DATA .................................................................. ERROR! BOOKMARK NOT DEFINED. 3.0 DESIGN & CONSTRUCTION ........................................................................................................ 5 4.0 MATERIAL REQUIREMENTS ....................................................................................................... 8 4.1 4.2 4.3 4.4 4.5 GENERAL ......................................................................................................................................... 8 VALVE BODY .................................................................................................................................. 9 BOLTING MATERIALS ................................................................................................................. 9 SEALS & GASKET MATERIALS .................................................................................................9 MATERIAL OF OPERATING DEVICES ..................................................................................... 9
5.0 INSPECTION AND TESTS............................................................................................................. 9 6.0 EXTENT OF INSPECTION & TESTING ...................................................................................... 13 7.0 TEST CERTIFICATES.................................................................................................................. 13 8.0 PAINTING, MARKING & SHIPMENT .......................................................................................... 14 9.0 SPARES & ACCESSORIES ........................................................................................................ 14 10.0 DOCUMENTATION ...................................................................................................................... 14 11.0 GUARANTEE ............................................................................................................................... 15
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BALL VALVE
1.0 SCOPE This specification defines the minimum technical requirements to be followed by the Vendor in the design, fabrication, testing, inspection, certification, marking, packing and delivery of carbon steel ball valves of ANSI class 150#, 300#, 600# for use onshore long distance pipeline systems including in station Handling of re-gasification and LNG in compliance with requirement of API-6D/BS-5351 and special requirement as described in this specification. 1.1 DEFINITIONS For this specification the following definition shall apply: OWNER CONSULTANT SHALL/MUST/IS TO BE: : : GAIL GAS LIMITED PDIL A mandatory requirement
1.2
APPLICABLE CODES AND STANDARDS Applicable reference codes and standards for the design and quality levels of the supply shall be the latest edition, which are the following: ASME STANDARD ASME B 1.1 ASME B 1.20.1 ASME B 16.5 ASME B 16.10 ASME B 16.20 Unified inch screw threads Pipe threads general purposes Steel pipe flange and flanged fittings. Face-to-face dimension of ferrous valves. Metallic gasket for flanges Ring, Point, Spiral wound and jacketed. Non metallic gasket for pipe flanges Butt welding ends Steel valves flanged threaded and Butt-welding end Surface Texture. Gas Transmission and Distribution piping system. Boiler & pressure Vessel code. all applicable sections.
ASME B 16.21 ASME B 16.25 ASME B 16.34 ASME B 16,46.1 ASME B 31.8 ASME
API Standard API 6D API 5L Specification for pipeline valves. Specification For pipe.
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API 6FA API 598 API 605 API 607
Fire Test for Soft Seated Ball valves. Valve Inspection and Testing. Large diameter carbon steel flanges. Fire Test for Soft-Seated Ball Valve.
BS Standards BS 5351 Steel ball valves for the petroleum, petrochemical and allied industries. Inspection and test of valves. Fire Safety of Valves Specification for steel globe and globe stop and check valves (flanged and butt-welding ends) for the petroleum, petrochemical and allied industries. Specification for steel wedge gate, globe and check valves 50 mm and smaller for the petroleum and allied industries.
BS 5146 BS 6775 Part I BS 1873
BS 5352
MSS- SP STANDARDS MSS SP-6 Standard finishes for contact face of pipe and connecting end flanges of valves and fitting. Standard marking system for valves, fitting, flange union. Steel pipeline flanges. Bypass and drain connection standard. Quality standards for steel casting. Radiographic inspection method. Quality Standard for Steel Casting for Valves, Flanges and Fittings and Other Piping Components Visual Method for Evaluation of Surface Irregularities. Ball valves with flanged or butt welding ends for general service. Specification for high test wrought butt-welding fittings Sulphide Stress Cracking resistance metallic Material for Oil Field Equipment. Quality assurance.
MSS SP-25 MSS SP-44 MSS SP 45 MSS SP 54
MSS SP - 55
MSS-SP-72 MSS-SP-75 NACE MR 0175
ISO 9000:
ASTM STANDARDS ASTM A53 Pipe, steel, black and hot dipped zinc coated welded and seamless Forgings, Carbon steel, for piping components.
ASTM Al05/A105M
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ASTM A106 ASTM A193/A193M
Seamless carbon steel pipe for high temperature service Alloy steel and stainless steel bolting materials for high temperature service. Carbon and alloy steel nuts for bolts for high temperatures service Pipe fittings of wrought carbon steel and alloy steel for moderate and elevated temperatures. Alloy steel bolting materials for low temperature service Forgings, carbon and low alloy steel, requiring notch toughness testing for piping components. Mechanical testing of steel products Metal arc welded steel pipe for use with high-pressure transmission system. Pipe fittings of wrought carbon steel and alloy steel for Low temperature service. Forgings, carbon and alloy steels, for pipe flanges fittings, valves and parts for high-pressure transmission service. Specification for steel, casting, carbon suitable for fusion welding for high temperature service.
ASTM A194/A194M
ASTM A234/A234M
ASTM A320/A320M ASTM A350/A350M
ASTM A370 ASTM A381
ASTM A420/A420M
ASTM A694/A694M ASTM 216 WCB
2.0 3.1
DESIGN & CONSTRUCTION The main line valves shall be of Double Block and Bleed, Type with double piston effect and suitable for low temperature application. They shall be of trunnion mounted type and suitable for buried and aboveground service with Cathodic protection service. The valve body shall be either fully welded for underground valve with extended stem and above ground body shall be fully welded or bolted. Valves body joints with threads are not acceptable. Valves shall be Butt Welded with pup pieces for underground and above ground installation. Flanged ends valves for above ground installation wherever applicable as per the requirement. The pipeline will be running in remote areas and subjected to severe environmental conditions. Hence the ball valves shall be free of any maintenance. The inside diameter of the valve bore and valve ends/pup pieces shall match the piggable lines internal diameter or the station piping internal diameter as per the requirement. Valve manufacturer shall be qualified according to API 6D / BS 5351. The selected Vendor shall prepare detailed documentations and procedures, for the Owner / Consultant approval based upon the requirements of this document and shall verify the applicability of the materials specified in these documents with the given fluid composition. The pressure temperature ratings of flanged or Butt welded end valves shall be as per ASME B 16. 34. Unless otherwise specified pipeline valves shall be suitable for use in re-gasified LNG transmission and distribution systems and shall be in accordance with ASME B31.8.
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a)
b)
c)
d) e)
f)
g)
h)
The temperature range and design pressure to be considered for the design of valves shall be as per that given in the data sheet. The wall thickness of valve used for welding connection with the line Pup pieces shall meet the following criteria. The maximum allowable stress in the material of the butt-welded connection shall be not greater than 50% of the minimum yield strength guaranteed by the specification of that steel. The minimum wall thickness for butt welding ends shall be greater than or equal to the largest valve of either the calculated minimum thickness of butt welding connection or nominal thickness of the pipe as per data sheet. Valve shall be provided with vent & drain connection.
I)
3.2
Valves shall be Full Bore (FB) as indicated in Valve Data Sheet. Full bore valves shall be suitable for the passage of all types of pipeline scraper and inspection pigs on regular basis without causing damage to either the valve component or the pig. The full-bore valve shall provide an unobstructed profile for pigging operations in either direction. Full bore valves shall be designed to minimize accumulation of debris in the seat ring region to ensure that valve movement is not impeded. * ** Nominal valve size corresponds to end connection. Nominal valve size corresponds to the minimum bore as listed in Table-I, API 6D.
3.3
Ball valve mounting shall be trunnion / pivot type as indicated in Valve Data Sheet. Valve design shall minimize the possibility of debris ingress into the trunnion as far as practicable. Valve seats shall be with primary metal to metal contact. O-rings or other seals, if used for drip tight sealing, shall be encased in a suitable groove in such a manner that it cannot be removed from seat ring and there is no extrusion during opening or closing operation at maximum differential pressure. The seat rings shall be so designed as to ensure sealing at low as well as high differential pressures. Seat design with PTFE insert is not acceptable. Valves shall have double block and bleed feature to facilitate complete flushing, draining and venting of the valve body cavity. For valves to be used in liquid service, the body cavity over-pressure shall be prevented by selfrelieving seat rings / assemblies. A pressure relief hole in the ball is not permitted. Self-relieving seat rings shall relieve at a body cavity differential pressure not exceeding 50% of the valve class rating pressure.
3.4
3.5
3.6
When specified in Valve Data Sheet, valves shall be designed to withstand a sustained internal vacuum of atleast 1 (one) milli-bar in both open and closed positions. Full Bore Valves shall have provision for secondary sealant injection under full line pressure for seat and stem seals. Sealant injection points shall be provided with a needle valve accommodating a grease fitting. Valves shall be provided with vent and drain connections. Valve design shall ensure repair of gland packing under full line pressure.
3.7
3.8 3.9
3.10
Face-to-Face / end-to end dimensions shall conform to API 6D.
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3.11
Valves shall be provided with ball position indicator and stops of rugged construction at the fully open and fully closed positions. Full Bore Valves shall be equipped with support foot and lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot shall be kept minimum. When indicated in Material Requisition, valves shall have locking devices to lock the vale either in full open (LO), or full close (LC) positions. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve. Valves shall be of fire resistant design as per API 607 / BS.6755 (Part-II) / API 6FA, as Indicated in Valve Data Sheet. Valves shall be provided with anti-static devices to ensure electrical continuity between stem / ball and valve body. Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high alloy steel components. Suitable insulation shall be provided as required. Valves shall be suitable for either buried or aboveground installation as indicated in Valve Data Sheet. When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions Valves provided with stem extension shall have waterproof outer casing and casing shall be designed keeping in view pipeline cathodic protection. Length of stem extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the distance between centerline of the valve opening and centerline of the rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a horizontal shaft. Vent and drain connections and sealant injections lines shall be terminated adjacent to the valve operator by means of suitable piping anchored to the valve body. Pipe used shall be API 5L Gr.B. Stem extension and stem housing design shall be such that the complete assembly will form a rigid unit giving a positive drive under all conditions with no possibility of free movement between valve body, stem extension or its operator. Outer casing of stem extension shall have 3/8 or NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion and seal weld of threaded connection for vent & drain shall be done as per valves manufacturer recommendation, if required. Valves shall have a Gear / Hydraulic / gas actuator or manual operator as indicated in Valve Data Sheet. In case of manual operator, valve sizes < DN 150mm (6 inches) shall be wrench operated and valve sizes > DN 219mm (8 inches) shall be gear operated. Valve design shall be such that damage due to malfunctioning of the operator or its controls will only occur in the operator gear train or hydraulic cylinder and that damaged parts can be replaced without the valve cover being removed. The power actuator shall be in accordance with the Purchaser specification issued for the purpose and as indicated in Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open / full open to full close under maximum differential pressure corresponding to the valve rating. For actuated valves, the actuator torque output shall be 1.50 times the break torque required to operate the ball valve under the maximum differential pressure corresponding to the valve class rating. For manual operator of all valves, the diameter of the hand wheel or the length of operating wrench shall conform to API 6D requirements and be such that under maximum differential pressure, the total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position. Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the
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3.12
3.13
3.14
3.15
3.16
3.17
a.
b.
c.
d.
e.
f.
g.
h.
valve. Hand wheels shall not have protruding spokes. i. Gear operators, when provided, shall have a self-locking provision and shall be fully encased, in waterproof / splash proof / dust proof / weather proof enclosure and shall be filled with suitable grease. Operating devices shall be designed for easy operation of the valve under maximum differential pressure corresponding to the valve rating. All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX. The procedure qualification shall include impact test and hardness test and shall meet the requirements of clause 4.6 and 4.8 of this specification, respectively. All welds shall be stress relieved in accordance with ASME Section VIII. Repair by welding is not permitted for fabricated and forged body valves. However, repair by welding as per ASME B16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall include impact test and hardness test and shall meet the requirements of clauses 4.6 and 4.8 of this specification, respectively. The tolerance on internal diameter and out of roundness at the ends for welded end valves shall be as per applicable connected pipe specification as indicated in Valve Data Sheet. Valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME Section VIII, Division I. In case of power-actuated valves, the valve stem shall be capable of withstanding maximum output of the power actuator. All valves under this specification shall be designed to withstand field hydrostatic test pressure with non corrosive water, after installation, during 24 hours when the gate, plug, ball or piston is partially open at a pressure level P= 1.5 times of design pressure during the test closure element shall not be removed. MATERIAL REQUIREMENTS GENERAL The materials for the valves components shall be selected by the Vendor according to data sheet. This material shall be approved by the Owner/Consultant prior to fabricating the valves; Certificates of chemical analysis and mechanical tests shall be issued for all the materials. The certificates shall be in accordance with the codes selected and be indicated in the drawings and QAP to be submitted for approval. Valve material shall conform to ASTM specifications stated in API 6D. 4.1.1 Unless specified otherwise Charpy V notch test on each heat of base material shall be conducted as per API 6D for all pressure containing parts such as body, end flanges, welding ends as well as bolting material for pressure containing parts. The Charpy V notch test requirements shall be as per "Specification for Submerged Arc Welded line pipe". For the Butt Welded valves body materials shall be readily field weldable, therefore carbon equivalent (CE) shall not exceed 0.40%. The maximum carbon equivalent shall be based on the following formula: Mn Cr+Mo+V Ni+Cu + ----------- + -------------- + -------------6 5 15
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j.
3.18
3.19 3.20
3.21
3.22
3.23
3.0 4.1
4.1.2
CE
4.2
VALVE BODY Valve body shall be of fully welded for underground installation. No repair welding on the valve body shall be done.
4.3
BOLTING MATERIALS Valve bolting should be ASTM A 193 Gr.7 and ASTM A 194 Gr.4 better for nuts.
4.4
SEALS & GASKET MATERIALS Valve seats shall be with primary metal-to-metal contact. O-rings or other seals, if used for drip tight sealing, shall be encased in a suitable groove in such a manner that it cannot be removed from seat ring and there is no extrusion during opening or closing operation at maximum differential pressure. The seat rings shall be so designed as to ensure sealing at low as well as high differential pressures. Metallic Seat materials shall be fire safe type satisfying the requirement of API 607 and API-6FA and certified by recognized third part agency. Fire safe gasket material shall be as per ANSI B 16.2 & B 16.21 respectively.
4.5
MATERIAL OF OPERATING DEVICES The hand wheel for manual operation of the valves shall be made of forged steel, welded rod or malleable cast-iron and wrenches of forged or pressed steel. Pressure containing components such as body, bonnet, cover and flanges manufactured in cast iron or ductile iron is not acceptable.
4.6
Charpy V Notch test on each heat of base material shall be conducted as per API 6D, for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy impact test shall be conducted at (-) 20 Deg.C. The Charpy impact test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27J with an individual minimum per specimen of 22 J. No specimen shall exhibit less than 80 percent shear area.
4.7
For all such valves, where carbon steel is used as ball material, the ball shall have 75 micrometer (0.003 inch) thick Electroless Nickel Plating (ENP) as per ASTM B733 with following classification: SC2, Type II, Class 2. The hardness of plating shall be minimum 50 RC. When specified in Valve Data Sheet, hardness test shall be carried out on each heat of base material for all pressure containing parts of the valve. A full thickness cross-section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV 10 based on minimum four measurements representing the entire thickness. All process wetted parts, metallic and non-metallic, shall be suitable for the fluids and service specified by the Purchaser. The service gas composition shall be as given in Annexure-I. INSPECTION AND TESTS The Manufacturer shall perform all inspection and tests as per the requirements of this specification and shall confirm to E10204 3.1b certification, prior to shipment, at his works. Such inspection and tests shall be, but not limited to, the following: All valves shall be visually inspected. Dimensional check on all valves shall be carried out as per the Purchaser approved drawings. Chemical composition and mechanical properties shall be checked as per relevant material
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4.8
4.9
5.0 5.1
5.1.1 5.1.2 5.1.3
standards and this specification, for each heat of steel used. 5.1.4 a) Non-destructive examination of individual valve material and components consisting of, but not limited to castings, forgings, plate and assembly welds shall be carried out by the Manufacturer. Body castings of all valves shall be radio graphically examined on 100% of the surface of critical areas as per ASME B16.34. All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B.16.34.
b)
All valves, with body fabricated from plates made or by forgings, shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure E of ASME B16.34. All forgings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B 16.34. Bodies and bonnets made by welded assembly of segments of castings, forgings, plates or combinations thereof shall be examined, as applicable, by methods of clause 5.1.4 b) for cast components or clause 5.1.4 c) for forged components and plates. Full inspection by radiography shall be carried out on all welds of pressure containing parts. Acceptance criteria shall be as per ASME B 31.4 or ASME B 31.8, as applicable, and API 1104. Welds which in Purchasers opinion cannot be inspected by radiographic methods shall be checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per ASME Section VIII, Division I, Appendix 12 and Appendix 6, respectively.
c)
5.1.5
5.1.6
5.1.7 a)
All finished wrought ends subject to welding in field shall be 100% ultrasonically tested for lamination type defects for a distance of 50mm from the end. Laminations shall not be acceptable. Weld ends of all cast valves subject to welding in field shall be 100% radio graphically examined and acceptance criteria shall be as per ASME B16.34. After final matching, all bevel surfaces shall be inspected by dye penetrant or wet magnetic particle methods. All defects longer than 6.35mm are rejected, as are defects between 6.35 mm and 1.59 mm that are separated by a distance less than 50 times their greatest length. Reject able defects must be removed. Weld repair of bevel surface is not permitted. PRESSURE TESTING
b)
c)
5.1.8
5.1.8.1 General requirements Each valve shall be tested by the Manufacturer under the supervision of the purchaser representative after final completion of all welding and all heat treatment operations. Hydrostatic and air seat tests shall be performed after an acceptable shell test. Fluid for shell and hydrostatic seat tests shall be liquid as water (which may contain a corrosion inhibitor), kerosene, or other fluid with a viscosity not greater than that of water. Temperature of the test fluid shall not exceed 50C. Valves shall be substantially relieved of air when tested with liquid. Valves shall be shell tested prior to painting.
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Valve test fixture loads applied to valve ends shall be limited to those required to effectively seal the valve ends. Pressure testing certificates shall be included in the CMTR (Certified Material Test Report). Drain, the sealant and the bleed valve shall be included in all pressure tests. If any supplementary welding, repair by welding or treatment are performed, valve shall be completely re-tested.
5.1.8.2 Shell test Each valve shall be given a shell test at the gauge pressure not less than 1.5 times the 38C rating gauged by ASME B16.34, rounded off to the next higher 1 bar increment. Shell test shall be conducted with the valve in a partially open position and with the valve ends closed. Drain lines and valves Shall be either included in the hydrostatic shell test, or tested separately. Duration of the shell test NPS up to 18 shall not be less than 15 minutes. NPS 20 and larger shall not be less than 30 minutes. Visual leakage or harmful inelastic deformation is not acceptable.
5.1.8.3 Hydrostatic seat test Each valve shall be given a hydrostatic seat test at the gauge pressure not less than 1.1 times the 38C rating gauged by ASME B16.34, rounded off t next higher 1 bar increment. Seat closure testing shall be performed with seat surfaces free of sealant, grease or other foreign material that aids in sealing except as provided hereafter.
When necessary to prevent damage during valve actuation, a light oil of viscosity not greater than that of kerosene may be applied to sealing surface.
When valve primary design is based on the presence of a sealant material (lubricated plug valve), the sealant material may be in place. For valve of the double seating type such as gate, plug and ball valve, the test pressure shall be applied successively to each end of the closed valve and leakage to opposite end checked. Provision shall be taken before, for de energising the self relieving pressure system.
For double block and bleed valve the following tests shall be performed : Close valve, open body vent, apply seat test pressure to both ends of the valve. Close valve, open body vent, apply seat test pressure to one end of the valve, release pressure and repeat test for the other end of the valve.
For double piston effect valve the following test shall be performed : Release pressure, close valve, open body vent, apply seat test pressure through the body vent.
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For other valve type, the test pressure shall be applied across the closure member in the direction producing the most adverse seating conditions. For example, a globe valve shall be tested with pressure under the disc. A check valve, globe valve or other valve type designed, sold and marked as a one-way valve, requires a closure test only in the appropriate direction. The duration of the hydrostatic seat test shall not be less than 5 minutes for each end. Visual leakage or harmful inelastic deformation is not accepted.
5.1.8.4 External leak testing Under the supervision of the purchase representative, the Manufacturer shall check the external leak tightness of body, stem and all external taps. This shall be done with soap suds at an inner pressure of 6 bars. For underground valves, this test shall include piping, fittings and valves of the auxiliary lines for drain, vent/bleed and sealant connections. 5.1.8.5 Air seat test Each valve shall be given an air seat test at 6 bars. This test shall be performed in the same manner as hydrostatic seat test. The duration of this test shall not be less than 5 minutes for each end. No signs of leakage are accepted.
5.1.8.6 Procedure Procedure of all pressure tests shall be included in the offer. 5.1.8.7 After tests After test, any auxiliary connections shall not be removed, and auxiliary piping shall be cleaned and dried, especially the sealant piping. 5.1.9 OPERATIONAL TORQUE TEST For valves operated with an actuator the Manufacturer shall perform an operational torque test at full rated differential pressure and at ambient temperature. The procedure must be included in the offer. The certificates shall be included in the CMTR (Certified Material Test Report). 5.1.10 FIRE TEST The Manufacturer shall supply valves qualified by fire testing as specified in API 6FA and this certificate shall be added to the CMTR (Certified Material Test Report). 5.1.11 ANTI-STATIC DEVICE TESTING If requested in the purchase order, all ball valves shall be submitted of to anti-static electricity testing in accordance with BS 5146 and this certificate shall be added to the CMTR. 5.1.12 VISUAL AND DIMENSIONAL EXAMINATION All valves shall be visually and dimensionally examined, according to API 1104 and MSS-SP-55. 5.1.13 A supplementary air seat test as per API 6 D shall be carried out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be held for atleast 15 minutes.
All rights reserved
5.1.14 Manufacturer who intends bidding, must submit at bid stage, certificate and report for successful fire type-tests for valves in accordance with API-607/BS: 6755(Part-II/API 6FA, as applicable in Valve Data Sheet. 5.1.15 Valves shall be subjected to Operational Torque Test as per supplementary test requirement of API 6D under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force required to operate the valve does not exceed the requirements stated in clause 3.17f & g of this specification. 5.1.16 Gas over oil actuated valves shall be tested after assembly of the valve and actuator at the valve Manufacturers works. Atleast five open-close-open cycles without internal pressure and five openclose-open cycles with maximum differential pressure shall be performed on the valve actuator assembly. The time for full open to full close shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the opening and closing times are within the limits stated in Actuator Data Sheet issued for the purpose. Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and the actuator model / type. In case the tests do not meet the requirements, retesting / rejection of the lot shall be decided by Purchasers Inspector. 5.1.17 When indicated in Valve Data Sheet, valves shall be subjected to anti-static testing as per supplementary test requirement of API 6D. 5.2 Purchaser reserves the right to perform stage-wise inspection and witness tests as indicated in clause 5.1 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchasers Inspector. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturers account. In no case shall any action of Purchaser or his Inspector relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed / witnessed by the Purchasers Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests. 6.0 6.1 EXTENT OF INSPECTION & TESTING Purchasers Inspector shall inspection and witness tests on all valves or as indicated in the Quality Assurance Plan (QAP) attached with this specification. Purchasers Inspection shall witness the hydrostatic testing and cyclic opening and closing of the valves with the operator. TEST CERTIFICATES Manufacturer shall submit the following certificates: Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for valve construction as per the relevant standards. Test certificates on hydrostatic and pneumatic tests complete with records of timing and pressure of each test.
All rights reserved
6.2
7.0 7.1 a.
b.
c. d. e.
Test reports on radiograph and ultrasonic inspection. Test report on operation of valves conforming to clause 5.1.11 and 5.1.12 of this specification. All other test reports and certificates as required by API 6D and this specification. The certificates shall be valid only when signed by Purchasers Inspector. Only those valves which have been certified by Purchasers Inspector shall be dispatched from Manufacturers works.
8.0 8.1
PAINTING, MARKING & SHIPMENT Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with Steel Structures Painting Council Visual Standard SSPC-IS-1. For valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of the buried portion of valves shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 400 microns. Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for approval. All valves shall be marked as per API 6D. The units of marking shall be metric except Nominal Diameter, which shall be in inches. Marking shall be done by die-stamping on the bonnet or on the housing. However, for buried valves the marking shall be done on the above ground portion of the stem housing only. Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable material. All valves shall be provided with suitable protectors, for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors. All sealant lines and other cavities of the valve shall be filled with sealant before shipment. Packaging and shipping instructions shall be as per API 6D. On packages, following shall be marked legibly with suitable marking: a. b. c. d. e. f. g. h. Order Number Manufacturers Name and Trade Mark Valve Size and Rating Tag Number Serial Number Maximum Operating Pressure Minimum and Maximum Operating Temperature (C) Body Material Designation (MSS-SP-25)
8.2
8.3
8.4
8.5 8.6 8.7
9.0 9.1
SPARES & ACCESSORIES Manufacturer shall furnish a list of recommended spares and accessories for valves required during start-up and commissioning. Manufacturer shall furnish a list of recommended spares and accessories required for two years of normal operation and maintenance of valves. Manufacturer shall quote for spares & accessories as per Material Requisition. DOCUMENTATION At the time of bidding, Manufacturer shall submit the following documents :
All rights reserved
9.2
9.3 10.0 10.1
a.
General arrangement / assembly drawings showing all features and relative positions and sizes of vents, drains, gear operator / actuator, painting, coating and other external parts together with overall dimensions. Sectional drawing showing major parts with reference numbers and material specification. In particular, a blow-up drawing of ball-seat assembly shall be furnished complying the requirement of clause 4.5 of this specification. Reference list of similar ball valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service, etc. Torque curves for the power actuated valves along with the break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves. Descriptive technical catalogues of the Manufacturer. Installation, Operational and Maintenance Manual. Copy of valid API 6D certificate, wherever applicable.
b.
c.
d.
e. f. g.
h.
Details of support foot, including dimensions and distance from valve, center line to bottom of support foot. Quality Assurance Plan enclosed with this tender duly signed, stamped and accepted.
i.
10.2
Within two weeks of placement of order, the Manufacturer shall submit six copies of, but not limited to, the following drawings, documents and specifications for Purchasers final approval: Detailed sectional arrangement drawings showing all parts with reference numbers and material specifications as referred to in clause 10.1 above. Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme. Complete dimensional details of support foot (where applicable) shall be indicated in these drawings as referred applied on the valves. Manufacturer of valves shall commence only after approval of the above documents. Once the purchaser has given the approval, any changes in design, material and method of Manufacturer shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured.
a.
b.
10.3
Within 30 days from the approved date, Manufacturer shall submit to Purchaser one reproducible and six copies of the approved drawings, documents and specifications as listed in clause 10.2 above. Prior to shipment, Manufacturer shall submit one reproducible and six copies of the following: Test certificates as per clause 7.0 of this specification. Manual for installation, erection, maintenance and operation instructions, including a list of recommended spares for the valves. All documents shall be in English language.
10.4 a) b)
10.5
11.0
GUARANTEE
All rights reserved
11.1
Manufacturer shall guarantee that the materials and machining of valves and fittings comply with the requirements in this specification and in the Purchase Order. Manufacturer is bound to replace or repair all valve parts which should result defective due to inadequate engineering or to the quality of materials and machining. If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace the valve without delay, Any defect occurring during the period of Guarantee shall be attended to by making all necessary modifications and repair of defective parts free of charge to the Purchaser as per the relevant clause of the bid document. All expenses shall be to Manufacturers account.
11.2
11.3
11.4
11.5
All rights reserved
4405-PNMP-TS-0929
TECHNICAL SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
Issued PURPOSE
AS
AKS
AKS
PREP D
REVWD
APPD
All rights reserved
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
SCOPE REFERENCE DOCUMENTS MANUFACTURERS QUALIFICATION MATERIALS DESIGN AND MANUFACTURE INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT DOCUMENTATION
All rights reserved
1.0
SCOPE This specification covers the minimum requirements for the design, manufacture and supply of following carbon steel flanges and fittings of size up to DN 400 mm (16") to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum' Gas (LPG): Flanges such as welding neck flanges, blind flanges, spectacle blinds, spacers and blinds etc. Seamless fittings such as tees, elbows, reducers, caps, outlets etc. Systems handling sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-01- 75.
2.0 2.1
REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition of the following Standards and Specifications: ASME B31.4 Hydrocarbons and Other Liquids ASME B31.8 ASME B16.5 ASME B16.9 ASME B16.11 ASME B 16.48 ASME Sec VIII/IX ASTM A 370 Testing of Gas Transmission and Distributors Piping Systems Pipe Flanges and Flanged Fittings Factory Made Wrought Steel Butt Welding Fittings Factory Made Wrought Steel Butt Welding Fittings Steel Line Blanks Boiler and Pressure Vessel Code Standard Test Methods and Definitions for Mechanical Steel Products. MSS-SP-25 and Unions MSS-SP-44 MSS-SP- 75 Standard Marking System for Valves, Fittings, Flanges Pipeline Transportation System for Liquid
Steel Pipeline Flanges. Specification for High Test Wrought Welded Fittings.
All rights reserved
MSS-SP-97
Forged Carbon Steel Branch Outlet Fittings - Socket Welding, Threaded and Butt welding Ends.
2.2
In case of conflict between the requirements of this specification and the requirements of above referred Codes and Standards, the requirements of this specification shall govern. MANUFACTURER'S QUALIFICATION Manufacturer who intends bidding for fittings must possess the records of a successful proof test, in accordance with the provisions of ASME B 16.9.
3.0
4.0 4.1
MATERIAL The Carbon Steel Used in the manufacture of flanges and fittings shall be fully killed. Material for flanges and fittings shall comply the material standard indicated in the Purchase Requisition. In addition, tile material shall also meet the requirements specified here in after.
4.2
Each heat of steel used for the manufacture of flanges and fittings shall have Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the following formula: CE = C + Mn / 6 + ( Cr + Mo + V ) / 5 + ( Ni + Cu )/15
4.3 For flanges and fittings specified to be used for Gas service or High Vapour Pressure (INP) liquid service, Charpy V -notch test shall be conducted on each heat of steel. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0 C in accordance with the impact test provisions, of ASTM A 370 for flanges and fittings. The minimum average absorbed impact energy values of three full-sized specimens shall be 27 joules. The minimum impact energy value of anyone specimen of the three specimens analyzed as above, shall not be less than 80 % of the above mentioned average value. For flanges and fittings specified to be used for other Hydrocarbon service, the Charpy V -notch test requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (L TCS) materials are specified in Purchase Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable material standard shall be Complied with. 4.4 For flanges and fittings, specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out in accordance
All rights reserved
Will ASTM A 370. Hardness testing shall cover at least 10% per item, per size, per heat, per manufacturing method. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV . For flanges and fittings, specified to be used for other hydrocarbon services, the hardness requirements stated above are not applicable. 4.5 5.0 5.1 In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. DESIGN AND MANUFACTURE Flanges such as weld neck flanges and blind flanges shall conform to the requirements of ASME Bl6.5. Spectacle blind and spacer & blind shall conform to the requirements of ASME B 16.48, Fittings such as tees, elbows, reducers, etc. shall be seamless type and shall conform to AS ME B 16.9 for sizes DN 50 mm (2") and above and ASME B 16.11 for sizes below DN 50 mm (2"). Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in accordance with MSS-SP-97. Type, face and face finish of flanges shall be as specified in Purchase Requisition. Flanges and fittings manufactured from bar stock are not acceptable. All butt weld ends shall be beveled as per ANSI B 16.5/ASME B 16.9/MSS-SP-97 as applicable. Repair by welding on flanges and fittings are not permitted. INSPECTION AND TESTS The Manufacturer shall perform all inspections and tests as per the requirement of this specification and the relevant codes, prior to shipment at his works. Such inspections and tests shall be, not but limited to the following:
5.2
5.3
5.4
5.5 5.6 5.7
5.8 6.0 6.1
6.1.1
All flanges and fittings shall be visually inspected. The internal and external surfaces of the fittings shall be free from any strikes, gauges and other detrimental defects. Dimensional checks shall be carried out on finished products as per ANSI B16.5 for flanges, ASME B 16.48 for spacers and blinds and ANSI B16.9/MSS-SP-97 as applicable for fittings and as per this specification.
All rights reserved
6.1.2
6.1.3
Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. All finished wrought weld ends subject to welding in field, shall be 100% tested for lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall not be acceptable. Purchaser's Inspector reserves the right to perform stage wise inspection and witness tests, as indicated in clause 6.1 of this specification at Manufacturer's Works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable Access and facilitates required for inspection, to the purchasers inspector. Inspection and tests performed/witnessed by Purchaser's Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests.
6.1.4
6.2
7.0
TEST CERTIFICATES Manufacturer shall furnish the following certificates:
a)
Test certificates relevant to the chemical analysis and mechanical properties of the Materials used for manufacture of flanges and fittings as per relevant standards and this specification. Test Reports on non destructive testing. Certificates for each fitting stating that it is capable of withstanding without leakage a test pressure, which results in a hoop stress equivalent to 100 % of the specified minimum yield strength for the pipe with which the fitting is to be attached without impairment of Serviceability. PAINTING, MARKING AND SHIPMENT After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection against corrosion during transit and storage. The coating shall be easily removable in the field. Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for fittings and flanges. Flange face shall be suitably protected to avoid any damage during transit. All flanges and fittings shall be marked as per applicable dimension/manufacturing standard. DOCUMENTATION
All rights reserved
b) c)
8.0 8.1
8.2
8.3
9.0
9.1
Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in Clause 7.0 of this specification. All documents shall be in English Language only.
9.2
All rights reserved
4405_5511_0051
0 REV
DOCUMENT NO
SHEET 1 OF 7
PIPELINE FOR CNG STATION PANVEL
GAIL GAS LIMITED
PIPING MATERIAL SPECIFICATION FOR CNG PIPELINE
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
AS PREPD
AKS REVW D
AKS APPD
All rights reserved
GENERAL PIPING SPECIFICATION MATERIAL TYPE CS CORROSION ALLOWANCE :1.5mm SERVICE - CNG
PROJECT NO.- 4405 PRESSURE RATING 150# MATERIAL TYPE API 5L-Gr.X-42
0 REV PIPE CLASS B24
PIPE
Nom.Dia SCH/WT.OR RATING Material Face Code Remarks
.5"-1.5" 2"-4" NIPPLE

Nom.Dia
SCH 80 SCH 40 SPECIAL

Wall thickness
API 5L-Gr.X-42 SMLS API 5L-Gr.X-42 SMLS
PE BW
ANSI B 36.10 ANSI B 36.10
NOTES 1
Material
Code
Remarks
0.5 1.5 FLANGE

Nom.Dia
SCH FROM PIPE
FROM PIPE
SPEC.ELEMENT
SCH/WT. OR RATING
Material
Face
Code
Remarks
0.5- 4
150#
A 105
SO-RF
ANSI B16.5
NOTE- 1
BLIND FLANGE
0.5- 4 ORIFICE FLANGE

N Nom.Dia Di
150#
A 105
RF
ANSI B 16.5
SCH/WT OR RATING SCH/WT.OR
M t i l Material
F Face
C d Code
R Remarks k
1- 4 GASKET
FLANGE DIAMETER
300#
A 105
WN-RF
ANSI B 16.36
NOTE-1
SCH/WT.OR RATING
Material
Gasket Type
Code
Remarks
0.5"- 4" BOLT SET

Nom.Dia
150#
AISI 304/ASBESTOS
Spiral Wound
API 601
NOTES 2
SCH/WT.OR RATING
Material
Face
Code
Remarks
0.5"- 4 FITTINGS
Nom.Dia BW
150#
ASTM A193-B7 ASTM A194 Gr.2H
ANSI B 16.5
ANSI B 18.2.2
SCH/WT.OR RATING
Material
Min. Dia
Code
Remarks
2- 4 FITTINGS
Nom.Dia SW
AS PIPE
A234-WPB
0.5 - 24
ANSI B 16.9
NOTES 1
SCH/WT.OR RATING
Material
Min. Dia
Code
Remarks
0.5" - 1.5" FITTINGS

Nom.Dia THD.
3000#
A105
0.5" - 1.5"
ASME B 16.11
NOTES 1
SCH/WT.OR RATING
Material
Min. Dia
Code
Remarks
0.5" - 1.5"
3000#
A105
0.5" - 1.5"
ASME B 16.11
FITTINGS
Nom.Dia
SPECIAL Wall thk. Material Min. Dia Code Remarks
2"- 4"
AS PIPE 3000#
A105
0.5" - 1.5"
MSS SP 97
NOTES 1,3
VALVES TYPES GATE VALVE BALL VALVE BALL VALVE
End Connection
Nom. Diam.
Code
Remarks
SW SW FLG
.5 - 1.5 .5 - 1.5 1.5 - 4
GAV 201 BAV 201 BAV 210
RADIOGRAPHY : POST WELD HEAT TREATMENT : IMPACT TEST :
ALL BUTT WELDS SHALL BE 100% RADIOGRAPHED SHALL BE AS PER MATERIAL GRADE AND STANDARD SHALL BE AS PER MATERIAL GRADE AND DESIGN REQUIREMENT
NOTES:
1. CARBON CONTENT C 0.25% 2. SPIRAL WOUND GASKET WITH OUTSIDE CENTRING RING IN CARBON STEEL 3. WITH REFERENCE TO BONNEY FORGE FOLLOWING TYPES ARE ALLOWED WELDOLETS,SOCKOLETS,THREDOLETS,ELBOLETS,NIPOLETS
GENERAL PIPING SPECIFICATION MATERIAL TYPE CS CORRSION ALLOWANCE : 1.5MM SERVICE CNG
PROJECT NO- 4405 PRESSURE RATING 300 # MATERIAL TYPE API 5L-Gr.X-42
0 REV PIPE CLASS D24
PIPE
Nom.Dia SCH/WT. OR RATING Material Face Code Remarks
.5"-1.5" 2"- 4" NIPPLE
SCH 80 SCH 40
API 5L-Gr.X-42 SMLS API 5L-Gr.X-42 SMLS
PE BW
ANSI B 36.10 ANSI B 36.10 NOTE-1
SPECIAL
Nom.Dia SCH/WT.OR RATING Material Code Remarks
0.5 1.5
SCH 80
FROM PIPE
API 5L
FLANGE
0.5-4
300#
A 105
WN - RF
ANSI B16.5
NOTE-1 WN TO MATCH THE PIPE
BLIND FLANGE
Nom.Dia SCH/WT.OR RATING Material Face Code
Remarks
0.5-4
300#
A 105
RF
ANSI B16.5
ORIFICE FLANGE
1-4
300#
A 105
WN - RF
ANSI B 16.36
NOTE-1
GASKET
Flange Diameter SCH/WT. OR RATING Material Gasket Type Code Remarks
0.5"-10" BOLT SET Flange Diameter 0.5"-10 FITTINGS

Nom.Dia
300#
AISI 304/ASBESTOS
Spiral Wound
API 601
NOTE-2
SCH/WT.OR RATING
Material
Face
Code
Remarks
300# BW
SCH/WT.OR RATING
ASTM A193-B7 ASTM A194 Gr.2H
RF
ANSI B 16.5
Material
Min.Dia
Code
Remarks
2-10
AS FOR PIPE
A234-WPB
0.5"-28"
ANSI B 16.9
NOTE-1
FITTINGS
Nom.Dia
SW
SCH/WT.OR RATING Material Min.Dia Code Remarks
0.5" - 1.5" FITTINGS

Nom.Dia
3000# THD.
SCH/WT.OR RATING
A105
0.5"-1.5"
ASME B 16.11
NOTE-1
Material
Min.Dia
Code
Remarks
0.5" - 1.5"
3000#
A105
0.5"-1.5"
ASME B 16.11
FITTINGS
Nom.Dia SPECIAL Wall thk. Material Min.Dia Code Remarks
2" - 10"
AS PIPE 3000#
A105
0.5"-1.5"
MSS SP 97
NOTE-1, 3
VALVES
TYPES End Connection Nom. Diam. Code Remarks
BALL VALVE BALL VALVE
SW FLG
.5 - 1.5 1.5 - 4"
BAV 202 BAV 211
RADIOGRAPHY : POST WELD HEAT TREATMENT : IMPACT TEST :
ALL BUTT WELDS SHALL BE 100% RADIOGRAPHED SHALL BE AS PER MATERIAL GRADE AND STANDARD SHALL BE AS PER MATERIAL GRADE AND DESIGN REQUIREMENT
` NOTES: 1. CARBON CONTENT C 0.25% 2. SPIRAL WOUND GASKET WITH OUTSIDE CENTRING RING IN CARBON STEEL 3. WITH REFERENCE TO BONNEY FORGE FOLLOWING TYPES ARE ALLOWED WELDOLETS,SOCKOLETS,THREDOLETS,ELBOLETS,NIPOLETS
PROJECT NO:- 4405 MATERIAL TYPE C.S CORROSION ALLOWANCE: 1.5mm SERVICE:CNG GENERAL PIPING SPECIFICATION PRESSURE RATING 600 # 0 REV PIPE CLASS F24
PIPE Nom.Dia Wall thk. Material Face Code Notes
.5"-1.5" 2"- 3" 4" - 18" NIPPLES
SCH 80 SCH 40 SCH 80
API 5L-Gr.X-42 SMLS API 5L-Gr.X-42 SMLS API 5L-Gr.X-42 SMLS
PE BW BW
ANSI B 36.10 ANSI B 36.10 ANSI B 36.10
1 1 1
SPECIAL Nom.Dia Wall thk. Material Rating Code Min. Diam. Notes
0.5 - 1.5 FLANGE Nom. Dia
SCH 80
API 5L-Gr.X-42 SMLS
SPEC. ELEMENT
Bore
Material
Rating
Type
Code
Notes
0.5 - 18"
AS PIPE
A 105
600 #
WN- RF
ANSI B 16.5
BLIND FLANGE Nom. Dia Bore Material Rating Type Code Notes
0.5- 18"
A 105
600 #
RF
ANSI B 16.5
ORIFICE FLANGE
Nom.Dia
Bore
Material
Rating
Type
Code
Notes
1 - 18"
AS PIPE
A 105
600 #
WN - RF
ANSI B 16.36
GASKET Flange Diameter Gasket Materials Flange Rating Gasket Type Code Notes
0.5 - 18"
AISI 304 / Asbestos
600 #
SPIRAL WOUND API 601
BOLT SET Flange Diameter Materials, Bolts/Nuts Flange Rating Flange Face Codes, Bolts / Nuts Notes
0.5 - 18"
A 193-B7/A 194-2H
600 #
RF
ANSI B 16.5 STUD BOLTS / B 18.2.2
FITTINGS
BW HEAVY HEX
Nom.Dia
Wall thk.
Material
Rating
Code
Min. Diam.
Notes
2 - 18
AS PIPE
A234-WPB
ANSI B 16.9
0.5 - 24
FITTINGS
SW
Nom.Dia
Wall thk.
Material
Rating
Code
Min. Diam.
Notes
0.5 - 1.5
A 105
3000 #
ASME B 16.11
0.5 - 1.5
FITTINGS
THD
Nom.Dia
Wall thk.
Material
Rating
Code
Min. Diam.
Notes
0.5 - 1.5
A 105
3000 #
ASME B 16.11
0.5 - 1.5
FITTINGS SPECIAL Nom.Dia Wall thk. Material Rating Code Min. Diam. Notes
2 - 18 2 18 AS PIPE
A 105 A 105
3000 #
MSS SP 97 MSS SP 97
0.5 - 1.5 218
1, 3 1, 3
VALVES
Nom. Dia
End Connection
Type
Code
Notes
2-8 2 18
FLG FLG
GLOBE VALVE BALL VALVE
GLV 212 BAV 222
NOTES:
1 CARBON CONTENT C 0.25 2 SPIRAL WOUND GASKET WITH OUTSIDE CENTRING RING IN CARBON STEEL. 3 WITH REFERENCE TO BONNEY FORGE FOLLOWING TYPES ARE ALLOWED WELDOLETS, SOCKOLETS, THREDOLETS, ELBOLETS, NIPOLETS. 4 BRANCH CONNECTIONS, TEES AND REDUCERS MAY BE FABRICATED FROM PIPE AND PLATE MATERIALS IN ACCORDANCE WITH ASME / ANSI 31.3. FULL SIZE TEE SHALL HAVE REINFORCEMENT OF COMPLETE TYPE.
4405_5511_0081
DOCUMENT NO REV SHEET 1 OF 4
PIPELINE FOR CNG STATION PANVEL GAIL GAS LIMITED
VALVE MATERIAL SPECIFICATION FOR CNG PIPELINE
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
AS PREPD
AKS REVW D
AKS APPD
FORM NO: 02-0000-0021F1 REV2
All rights reserved
4405-PNMP-TS-0930
TECHNICAL SPECIFICATION FOR INSULATING JOINTS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREPD
REVWD
APPD
TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 SCOPE REFERENCE DOCUMENTS MATERIALS DESIGN & CONSTRUCTION REQUIREMENTS INSPECTION & TESTS TEST CERTFICATES PAINTING, MARKING AND SHIPMENT GUARANTEE DOCUMENTATION
1.0
SCOPE This specification cover the basic requirements for design manufacture, testing and supply of carbon steel insulating joints to be inastalled in onshore pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquified Petroleum Gas (LPG).
2.0
REFERENCE DOCUMENTS
2.1
Reference has been made in this specification to the latest edition of, the following Codes, Standards and Specifications. a) ASME B 31.8 Gas transmission & Distribution piping System. b) ASME B 31.4 Liquid transportation systems for hydrocarbons, LPG, Anhydrous Ammonia and Alcohols. Mechanical testing of Steel Products. Butt Welding Ends. Boiler & Pressure Vessel Code viii & ix Standard for welding pipelines and Related facilities. Steel Structures painting Council Visual Standard. Quality standard for steel castings and forging for valves flange and fittings and other piping components magnetic particle examination method. Specification for high test wrought welding fittings. The electrical isolation of cathodically protected pipelines.
c) ASTM A 370 d) ANSI B 16.25 e) ASME Section f) API 1104 g) SSPC-VIS-1 h) MSS-SP-53
i) MSS-SP-75 j) NACE RP 0286 2.2
In case of conflict between the requirements of this specification and any code, Standard or Specification refferred to in this Specification, the requirements of this specification shall govern.
3.0 3.1
MATERIALS Material for pups shall be equilavent or superior to the material of connecting pipeline. Other part shall be as per manufacturers standard suitable for the services condition indicated in insulating Joints data Sheets and shall be subject to approval by perchaser.
3.2
Insulating joints which are subject to field welding by purchaser shall have carbon equivalent (CE) not exceeding 0.45 based on check analysis for each heat of steel calculation according to the following formula: CE= C+ Mn/6 + (Cr+ Mo+ V)/5 + (Ni + Cu)/15
3.3
When specification in the IJ Data Sheet, charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of 00 C. The Charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Avrage impact energy value of three full sized specimens shall be 27 joules. Minimum impact energy value of any one specimen shall not be less than 80% of the average impact energy specified. No specimen shall exhibit less than 80% shear aera.
3.4 3.5
Carbon steel used for the manufacture shall be fully killed. When specified in data sheet, hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise. Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286. DESIGN & CONSTRUCTION REQUIREMENTS Mechanical
3.6
4.0 4.1
4.1.1 Insulating joints shall be of integral type fabricated by welding and with pups on either side as shown in data sheet. A corrosion allowance as indicated in data sheet shall be considered in design. Bolted and threaded joints are not acceptable. 4.1.2 All materials used for the manufacture of the insulating joint shall be in accordance with clause 3.0 of this specification. 4.1.3 Insulating joints shall be designed using the design principles of ASME Section-VIII Div. 1. The design shall be checked for the following two cases : Case-I: Design Pressure (as per data sheet ) + Axial Force (F)
The Axial Force shall be calculated as under: F = 0.1 x S x A Where S = SMYS of connected pipe (refer Data Sheet) A = Metal cross-sectional area of coneected pipes.
The allowable stress in this case shall be less than or equal to 0.5 x SMYS of insulating joint material. Case-II: Hydrostatic Test Pressure The allowable stress in this case shall be less than or equal to 90% of SMYS of insulating joint material. All design parameters shall be as per Insulating Joint Data Sheet. Detailed calculations shall be submitted for Purchaser approval.
4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to 1 millibar. 4.1.5 The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld design shall be such as resulting in a weld joint factor of 1.0. 4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding ends having unequal thickness with respect to connecting pipe, shall be a s per ASME B31.4/ B31.8 as applicable. 4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed for a distance of atleast 50mm from each end. 4.1.8 Insulating joints shall allow free passage of scraper / instrumented pigs. The internal bore shall be same as that of connecting pipe including its tolerances. 4.1.9 The insulating joint shall be formed by sandwiching and locking in positions the insulating material in a bell and spigot type of joint. The joint shall be assembled in such away that its various componenets are locked in position and the completed joint is capable of withstanding stresses due to designed operating conditions and field hydrostatic testing. 4.1.10 Insulating joints shall be suitable for aboveground or underground installations as indicated in the data sheets. 4.1.11 All welds shall be made by welders and welding procedures qualified in accordance with the provisions ASME section IX. The procedure qualification shall include impact test and hardness test and shall meet the requirements of clause 3.3, 3.5 of this specification. 4.1.12 Repair welding on parent metal is not allowed. Repair of weld shall be carried out only after specific approval by purchasers representative for each repair. The repair welding shall be carried out by welders and welding procedures duly qualified as per ASME section IX and records for each repair shall be maintained.
4.1.13 Internal diameter at the welding end shall not vary more than +1, -3 mm from the nominal internal diameter.
4.1.14 Out of roundness measured at the root face of the welding ends shall not be more than 0.5% of the specified inside diameter. 4.2 Electrical
4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kilo volts. 4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either side of the insulating joint for connecting 10 mm2 and 50 mm2 cables for measurement/ shorting purposes. Cleats shall be attached to the insulating joint by welding.
5.0 5.1
INSPECTION AND TESTS The manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment at his works. Such inspection and tests shall be, but not limited to the following:
5.1.1 All insulating joints shall be visuall inspected. 5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings. 5.1.3 Chemical composition and mechanical properties including hardness shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below: a) 100% radiography shall be carried out on all butt & repair welds of pressure containing parts. Acceptance limits shall be as per API 1104. Welds which in purchasers representative opinion cannot be inspected by radiographic methods shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME section VIII Appendix-12 and Appendix-6 respectively. b) All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a distance of 50mm from the ends. Any lamination larger than 6.35mm shall not be acceptable. All forgings shall be wet magnetic particle inspected on 100% of forged surfaces. Method and acceptance shall comply MSS-SP-53. All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle inspection and > 6mm shall be examined 100% by UT. Acceptance criteria for MPI & UT shall be as per ASME sec.VIII Appendix-6 & Appendix-12 respectively.
c) d)
5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data sheet. The test duration shall be of 15 minutes.
5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage will be accepted. 5.1.7 Dielectric Test a) b) Insulating resistance of each insulating joint shall be atleast 25 mega-ohms when checked with 500-1000 V DC. Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic test shall be equal. Testing time voltage and leakage shall be recorded and certified. No repair shall be permitted to the insulating joints failed in the above mentioned tests.
5.2
Purchaser reserves the right to perform stagewise inspection and witness test as indicated in Para 5.1 at manufacturers works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection to the purchasers Representative. Inspection and tests performed/witnessed by the Purchasers representative shall in no way relieve the manufacturers obligation to perform the required inspection and tests.
6.0 6.1
TEST CERTIFICATES Manufacturer shall submit following certificates to Purchasers representative. a) Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for construction of insulating joint as per this specification and relevant standards. Test reports on non-destructive testing. Test cerificates for hydrostatic and air tests. Test certificates for electrical test. Test report on vacuum test.
b) c) d) e) 7.0 7.1
PAINTING, MARKING AND SHIPMENT Insulating joint surface shall be throughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with steel structures paintin council visual standard SSPC-VIS-I. External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. Insulating joints shall be marked with indelible paint with the following data:a) b) c) Manufacturers name Suitable for inch nominal diameter pipeline End thickness in mm
7.2
d) e) f) g) h)
Material Design pressure/Hydrostatic test pressue ANSI Class rating Tag No. Year of manufacture
7.3 Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel protectors shall be provided to weld ends. 7.4 Only those insulating joints which have been inspected and certified by Purchaser shall be shipped. GUARANTEE
8.0
8.1 The manufacturer shall guarantee that the materials used comply with the requirements of this specification. 8.2 Manufacturer shall replace or repair insulating joints found defective due to inadequate engineering or quality of material. 8.3 Manufacturer shall replace the insulating joint without delay if thedefect or malfunctioning cannot be eliminated. 8.4 Any defects occuring within 12 months from the date of installation or within 30 months from the date of despatch, whichever is earlier, shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser. 9.0 9.1 9.2 DOCUMENTATION All documents shall be in English Language. At the time of bidding, Bidder shall submit the following documents:a) b) c) General arrangement drawing along with cross sectional view, overall dimensions and details of insulating materials recommended. Reference lists of previous supplies of insulating joint of similar specification. Clausewise list of deviation from this specification, if any.
9.3 Within three weeks of placement of order, the manufacturer shall submit four copies of but not limited to the following drawings, documents and specifications for approval. a) b) c) Fabrication drawings and relevant calculations for pressure containing parts. Welding procedure and method of manufacture for all phases of manufacture. Quality Assurance Plan (QAP).
Once the approval has been given by purchaser any changes in design, material and method of manufacture shall be notified to the Purchaser whose approval in writing of all changes shall be obtained before the insulating joint are manufactured.
9.4
Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies of the approved drawings, documents and specifications as listed in 9.3 of this specification. Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test certificates as listed in Clause 6.0 of this specification.
9.5
4405-PNMP-TS-0931
TECHNICAL SPECIFICATION FOR STAINLESS STEEL TUBES FOR CNG
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
AS
AKS
PREPD
REVWD
APPD
TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 SCOPE CODES AND STANDARDS PRECEDENCE / CONFLICT RESOLUTION DEVIATIONS TUBE MANUFACTURING FACILITIES SPECIFICATIONS OF SS TUBES DOCUMENTATION
1.0 1.1
SCOPE The scope of the bidder includes but not limited to manufacture, supply, inspection & testing at work shop marking, packing, handling and dispatch of SS tubes, as per quantities given in SOR and complying all the requirements as per ASTM A269. All codes and standards for manufacture, testing, inspection etc. shall be of latest edition. Owner (GAIL GAS LTD.) 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. CODES & STANDARDS Applicable Codes and Standards to be followed are as under but not limited to the following:a) ASTM A 269 Standard Specification for Seamless and Welded austentic stainless steel Tubing for general services. Process Piping Standard Specification for general requirements for carbon, ferritic alloy and austentic alloy steel tubes.
1.2
1.3
2.0
b) ANSI B 31.3 c) ASTM A 450
3.0
PRECEDENCE / CONFLICT RESOLUTION In case of any conflict between this specification, Codes & Standards and other document, the following order of precedence shall apply:-
3.1 3.2 4.0
Technical Specification for Stainless Steel Tubes for CNG. Applicable International Standars / Codes. DEVIATIONS Technical deviations, if any, required by bidder shall be separately furnished again each clause giving reasoning for each deviation. Bidder to note that except the deviation furnished by them, Bidders offer shall be deemed to be in total conformity with the enquiry / tender specifications.
5.0 5.1
TUBE MANUFACTURING FACILITIES Tube manufacturer shall have integrated production facility that covers steel melting the finished product. In case the tube manufacturer is outsourcing the hollows then the same supplier should be identified and approved before order placement and all hollows should be outsourced from the same supplier.
5.2
Tube manufacturer shall be ISO 9001 / 9002 etc. certified.
6.0
SPECIFICATIONS OF SS TUBES All the items shall be suitable for compressed natural gas service and meet following specifications.
6.1
Tube material shall be stainless steel and shall have dual certification of TP 316/ 316L as per ASTM A213/ A269. Tube shall be bright annealed. Tube shall be seamless. Tubing should have Molybdenum & carbon content as per ASTM A269 Grade TP 316/316L (i.e. Mo content of 2.00 3.00 % and a max. carbon content of 0.035%). Tube hardness shall be less than Rb 80. Tubes shall be NACE MR 0175 certified for hardness. Hardness test shall be carried out on each tube. Each tube shall be hydro tested as per requirement of ASTM A450 clause 22.3, at a hydro test pressure of 350 kg/cm2 (g). However, it shall be ensured that the test pressure does not result in stresses exceeding the yield strength at test pressure. The min. tensile strength & yield strength shall be verified by a means of tensile strength. All S.S. tubes shall be online 100% eddy current tested as per ASTM A 450. Tolerance on outer diameter shall be 0.005. Tube shall be of 6 meter in length with tolerance as per ASTM A 269 (Under 0 mm, Over 3.2 mm).
6.2 6.3 6.4
6.5
6.6
6.7
6.8 6.9 6.10
6.11
Minimum thickness shall be as per following table. Tube OD 1 Minimum Wall Thickness 0.109 0.095 0.065
6.12 i) ii) iii) iv)
Following documents/certificates to be submitted before inspection. Chemical composition for heat Chemical composition for products Tensile test Hardness test
v) vi) vii) viii) 6.13
Flaring test Eddy current test Leak test Visually inspection and dimensional check
Tubing should be clearly marked with specification given in the inspection certificate with heat code, lot code, outer diameter and wall thickness with inspection certificate no. Tubes should be supplied with both ends plugged with clean interiors & each packing containing tubes shall carry the following stamped or written in inedible ink, manufacturers name or trade mark, designation of tubes, lot no. etc. DOCUMENTATION All documents shall be furnished in English Language only. At the time of bidding, bidder shall submit following documents. Reference list of previous supply of similar item, giving following details. a) b) c) d) e) f) Name of the customer. Specification of the item i.e., size & pressure & temperature rating. Service Quantity Year of supply Copy of third party inspection certificates.
6.14
7.0 7.1 7.2 i)
ii) iii) iv) v) 7.3
Copy of ISO: 9001 / 9002 etc. certfication for supplier/ manufacturer. Manufacturer Quality control plan Clause wise deviations to the specification. Technical descriptive catalogue of manufacturer. Following test certificates as per EN 10204 3.2 shall be furnished along with shipment: a) b) c) d) Test certificate of visual, chemical, mechanical testing (incl. Tensile, hardness, flaring and leak test). Manufacturers standard shop inspection & test report for all sizes of items. The test report for specified tests. Third party inspection report as applicable to meet the requirements of specific codes & standards as applicable.
8.0 8.1
INSPECTION AND TESTING Inspection shall be carried out as per GAIL GAS LTD. Technical specifications, relevant codes/standard and Inspection Plan/ QAP. Vendor to prepare detailed QAP and submit the same for approval of GAIL GAS LTD. / GAIL GAS LTD. Authorised representatives.
8.2
Vendor shall furnish all the material test certificates, proof of approval/ license from specified authority as per specified standard, if relevant, internal test/ inspection reports as per GAIL GAS LTD. Technical specification and specified code for 100% material, at the time of final inspection of each supply lot of material. Even after third party inspection, GAIL GAS LTD. reserves the right to selct a sample of tube randomly from each manufacturing batch ve these independently tested. Should the results of these tests fall outside the limits specified in GAIL GAS LTD. Technical specification, then GAIL GAS LTD. reserves the rights to reject all production supplied from the batch. For any control test or examination required under the supervision of TPIA/owner/owners representative, latter shall be informed in writing one (1) week in advance by vendor about inspection date & place along with production schedule.
8.3
8.4
4405-PNMP-TS-0932
TECHNICAL SPECIFICATION FOR SUPPLY, ERECTION & COMMISSIONING OF FIRE FIGHTING EQUIPMENTS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS PREPD
AKS REVWD
AKS APPD
TECHNICAL SPECIFICATION FOR SUPPLY, ERECTION COMMISSIONING OF FIRE FIGHTING EQUIPMENTS
CONTENTS
1.0 2.0 3.0
SCOPE PORTABLE FIRE EXTINGUISHERS AND FIRE SAND BUCKETS SCHEDULE OF REQUIREMENT
1.0
SCOPE Scope of works shall include design, engineering, supply, test at works, transportation, transit insurance, loading, unloading and stacking at site and complete on site erection, testing and commissioning including insurance till commissioning and putting into operation Fire Extinguishers and Fire Sand Buckets required for various systems of fire fighting system.
2.0
FIRE EXTINGUISHERS AND FIRE SAND BUCKETS
2.1
DCP TYPE EXTINGUISHER Portable dry chemical powder type fire extinguishers shall be provided as ready means for dealing effectively and immediately with fire in the CNG Compression station. Following types of fire extinguishing equipment as per the Schedule of Requirements shall be provided.
a.
Supply and installation of 10 Kg capacity dry chemical powder (DCP) type fire extinguisher with extinguishers cabinet suitable for inverted operation and fabricated from MS sheet internally protected with anticorrosive treatment and hydraulically tested. Extinguishers shall be externally painted with red enamel paint. Manufacturing code IS: 13849. Supply and installation of 75 Kg capacity trolley mounted dry chemical powder (DCP) type fire extinguisher suitable for inverted operation fabricated from MS sheet internally protected with anticorrosive treatment and hydraulically tested extinguishers externally painted with red enamel. Manufacturing code IS: 10658. FIRE EXTINGUISHER CARBON-DIOXIDE TYPE Supply and installation of 4.5Kg capacity CO2 type fire extinguishers with steel cylinder with discharge valve and conforming to IS: 2878-1975. Extinguisher shall be painted with red enamel paint and hardware/ bracket required for fixing to wall.
b.
2.2
2.3
FIRE SAND BUCKETS Providing & installation of galvanized mild steel fire buckets of 9 litres capacity, made as per IS: 2546 including supplying & fixing of MS angle iron stand to accommodate 4 nos. of fire buckets and first fill with sand all complete as per direction of Engineer In charge. (One set consisting of 4 buckets with stand). The bucket should be well labeled so that, in case of emergency, it is easy to spot and use. The sand must also be cleaned of all flammable material. Fire buckets shall be filled with clean dry sand conspicuously marked.
3.0
SCHEDULE OF REQUIREMENT
SR.NO.
DESCRIPTION
CAPACITY
QUANTITY
REMARKS
1 2 3 4
DCP Type Fire Extinguishers conforming to IS: 13849 DCP Type Fire Extinguishers conforming to IS: 10658 CO2 Type Fire Extinguishers conforming to IS: 2878-1975 Fire Sand Buckets (4Nos. Each set) conforming to IS: 2546.
10 KG 75 KG 4.5 KG 9 LTRS.
8 2 4 4
Note: - The equipments are to be purchased from the Vendor list enclosed as per Annexure -1.
ANNEXURE -1
LIST OF VENDORS FOR FIRE FIGHTING EQUIPMENT
1. Nitin Fire Protection Pvt. Ltd., Mumbai. 2. Safex Fire Services, Mumbai. 3. Fire Safety Services, New Delhi. 4. HD Fire Protect Co., Thane. 5. Zenith Fire Services, Mumbai. 6. Steelage Industries, New Delhi. 7. Atlas Firetech Pvt. Ltd., Delhi.
4405-PNMP-TS-0933
0 REV
SPECIFICATION FOR FLEXIBLE FILL HOSE
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS
PRS/AS
AKS
PREPD
REVWD
APPD
4405-PNMP-TS-0933
0 REV
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0
SCOPE CODES AND STANDARDS SPECIFICATIONS TEST REPORTS & CERTIFICATES MARKING, PACKING & SHIPMENT WARRANTY
4405-PNMP-TS-0933
0 REV
1.0 1.1
SCOPE The scope of this specification covers the requirement of design, manufacture/ inspection/ testing at the works/ marking/ packaging/ and supply of flexible fill hose for Mobile Cascades filling complete with all auxiliaries and features required for efficient and safe operation. CODES AND STANDARDS Unless otherwise specified elsewhere in this specification Flexible fill Hose and their installation shall conform to the latest revisions of codes and standards listed below. ITEM HOSE (For CNG Application) END CONNECTIONS APPLICABLE CODES & STANDARDS NFPA-52, AGA1-93, ANSI-4.2112.52
2.0
ASTM A 276, ASTM A 479, ASME SA 479, ASTM A 262, Practice-A to E and or EN ISO 3651-2, Method A. NPT ANSI B 1.20.1
THREAD
3.0
SPECIFICATIONS The specifications described herewith are intended to give vendor the technical and operating conditions the Flexible Fill Hose should fulfil. Vendor may indicate in his offer, the additional features, which his Flexible fill Hose has in terms of better design, enhance reliability etc., however such feature may be accepted subject to clients review and approval. Each Flexible Fill Hose should have the following specifications:1. The core material shall be non-metallic, electrically conductive, thermoplastic flexible hose of 5 feet length with both ends 3/8 OD SS 316 tube adapter end connection and spring guard in complete conformity with the relevant codes & standards as mentioned above. 2. Two or more layers of fibre reinforcement. 3. Thick layer of abrasion resistant Polyurethane Black cover to prevent abrasion and display better wear resistance shall be provided on the hose. 4. Electrical conductivity shall comply with AGA1-93. 5. End Connections shall be SS-316 material conforming to relevant Design standards as specified above. 6. The whole assembly shall be rated for a working pressure of 5000 psig and shall be rated for temp. Range of -40 to 250F.
4405-PNMP-TS-0933
0 REV
7. Vendor shall also include supply of Breakaway coupling, suitable for NGV Industry, in each hose. 8. Specific conductivity of Filling Hose shall be 0.512 Mega ohms for lengths up to 180 (approx. 4.5 Mtr.) and 3.5 Mega ohms for length over 180 and up to 1200 (approx. 30 Mtr.). 9. Minimum Burst Pressure of Flexible Fill Hose shall be four times the working pressure.
4.0
TEST REPORTS AND CERTIFICATES 1. The manufacturer shall supply material compliance certificate. 2. The manufacturer must submit product type test reports for the following tests conducted on CNG Hoses: a. Hydraulic Burst Pressure Test b. Hydraulic Proof Pressure Test c. Hydraulic Leakage Test d. Change in Length Test.
5.0
MARKING, PACKING & SHIPMENT 1. All hoses shall be duly marked with the manufacturers name, series, material, hose size and all relevant standards applicable. 2. All the items shall be suitably wrapped and packaged to withstand rough handling during ocean shipment and inland journey. 3. Each item shall be properly tagged and packaged separately to facilitate easy identification. 4. All items shall be wrapped and packaged in such a way that they can be preserved in original as new condition.
6.0
WARRANTY 1. Manufacturer shall guarantee that the design, materials, manufacturing and testing of CNG Hoses comply with the requirement of this specification and applicable codes and standards. Manufacturer shall replace if resulted defective or fail during field pressure testing or fail to perform satisfactorily due to inadequate engineering, substandard material and workmanship. 2. The manufacturer shall guarantee against any defect, failure or malfunctioning occurring during 12 months from the date of commissioning or 24 months from the date of supply whichever is earlier.
4405-PNMP-TS-0934
TECHNICAL SPECIFICATION FOR SS FERRULE FITTINGS FOR CNG REFILLING STATIONS
0 18.02.09 REV REV DATE
18.02.09 EFF DATE
Issued PURPOSE
PRS PREPD
AKS REVWD
AKS APPD
TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 SCOPE OF WORK CODE & STANDARD PRECEDENCE DEVIATION SPECIFICATION MARKING, PACKING & SHIPMENT DOCUMENTATION GUARANTEE
1.0 1.1
SCOPE OF WORK The scope of this specification covers the requirement of design, manufacture/ inspection/ testing at the works/ marking/ packaging/ and supply of high pressure SS Ferrule Fittings.
2.0
CODES & STANDARD The latest editions of the following standards are referred to in this specification.
Items Bar Stock Forging Thread
Applicable Codes and Standards ASME SA-479-316 or DIN 4401 or BS:970-316S31 ASME SA-182-316 or DIN 4401 or BS:970-316S31 NPT ANSI B 1.20.1
3.0 3.1 3.1.1 3.1.2 4.0
PRECEDENCE In case of any conflict between this job specification and other document, the following order of precedence shall apply: Job Specification. International Standards/ Codes Applicable. DEVIATION Deviations if any required by Tenderer shall be separately furnished against each clause giving reasoning for each deviation. Tenderer to note that except the deviations furnished by them, Tenderers offer shall be deemed to be in total conformity with the enquiry specifications.
5.0
SPECIFICATION All the items shall be suitable for compressed Natural Gas services and meet following specifications.
5.1
Materials
5.1.1 I) II) 5.1.2 5.1.3 5.1.4 5.2 5.2.1
Fitting shall be manufactured from the following materials:Bar stock shall be as per BS: 970-316-S31, DIN 4401 or ASME 479-316 but with carbon content less than 0.05% to provide increased resistance to corrosion. Forgings shall be as per BS: 970-316-S31, DIN 4401 or ASME SA-182-316. The fittings end connections shall be compatible to tube of hardness Rb80. All component parts of the fitting shall be of the same material. The ferrule material shall be able to withstand an atmosphere of Natural Gas, oil and moisture without rusting. Design & Manufacture All fittings shall be designed in conformance with the requirements of ASME B31.3 and applicable standards. Area classification applicable for all items shall be Class -1, Division-1, Group-D as per NEC or Zone -1 Group-IIA /IIB as per IS/IEC specification or equivalent specification. All fittings shall be designed so that all parts/ components meet the requirements for the specified area classification. The SS fitting shall be of flareless design and four piece constructions, consisting of front and rear ferrules, nut and body suitable for use on SS tubes confirming to ASTM A269 TP316. Fittings shall be rated for at least the design pressure as stipulated in the material requisition. The design of fittings shall ensure that they shall be capable of holding full tube burst pressure after only one and a quarter turn pull up of the nut. The threaded ends of fittings shall be NPT as per ANSI B1.20.1. The fitting shall hold the tube with colleting action producing a firm grip on the tube without substantially reducing the tube wall thickness.
5.2.2
5.2.3
5.2.4 5.2.5
5.2.6 Fittings shall not torque the tubing original or subsequent make-up of the connection and should use geometry for inspection before and after make up the fittings shall not require disassembly for inspection before or after make up. 5.2.7 All tube fittings shall be gaugeable for sufficient pull up after one and a quarter turn. All tube fitting shall have a gaugeable shoulder and there will be no radius at the point where the shoulder meets the neck of the fitting body. The gap inspection gauge shall be easily insertable at finger tight position of nut. The gap inspection gauge shall not be insertable between the nut and shoulder of the fitting after completing only one and a quarter turn pull up the nut.
5.2.8
5.2.9
The tube set counter bore in the body shall be faced flat 900 to the axis of the tubing to minimize tube expansion and subsequent galling.
5.2.10 The sealing and gripping power of the fitting shall be controlled such that the action between ferrules will overcome commercial variations in tubing wall thickness, hardness, diameter and installer skill. 5.2.11 The seal contact areas of the fittings body shall have a machined finish of 32 Ra or better. 5.2.12 The fittings body shall have no machined stop or shoulder to preclude additional tightening in subsequent make-up. 5.2.13 Front Ferrule i) ii) The front ferrule shall effect a long, smooth repeatable seal by contact with body and a grip hold on the tube surface. The front ferrule shall always remain in a sprung condition to compensate for thermal stresses and to accomplish repeated make and break.
5.2.14 Rear Ferrule i) ii) The rear ferrule shall collect the tubing surface, improving the performance of the tubing in systems of high impulse or vibration. The rear ferrule may have a machine recess on the inside diameter and shall have complete surface hardening so as to substantially reduce the required pull up torque.
5.2.15 Nuts shall have silver plated threads to act as a lubricating agent to avoid galling and to reduce tightening torque. 5.2.15 Inspection and Testing 5.3.1 I) II) III) The manufacturer shall submit typical type test reports for the following test carried out on random samples of two ferrule fittings:Hydraulic burst pressure test. Helium leak test under 0.0002 PSIA negative pressure, leaks into assembly greater than 4.0 x 10-9 atm-cc/sec being unacceptable. Gas pressure test for 25 remarks at 5000 Psig. No leakage should be detectable even after 25 remarks.
IV)
Impulse & vibration testing by rotary beam method for 5,00,000 impulse cycles and 20 million vibration cycles with no detectable leakage at full working pressure throughout till the end of the test. Test Reports and Certificates The manufacturer shall supply material compliance certificates conforming that the raw material for fittings conforms to the requirements of ASME Section-II and ASME Section-III sub section NB, NC and ND. The manufacturer shall furnish test procedure and typical test reports of all tests conducted on fittings as per the requirements of clause 5.3. MARKING, PACKING & SHIPMENT Heat code traceability number shall be stamped or etched on both body and nut of each fitting. Replacement nuts and ferrules shall be packaged in a manner so as to allow safe and simple replacement. All the items shall be suitably wrapped and packaged to with stand rough handling during ocean shipment and inland journey. Item shall be properly tagged and package separately to facilitate easy identification. Item shall be wrapped and packaged in such-a- way that they can be preserved in original as new condition. DOCUMENTATION All documents shall be furnished in English language only. At the time of bidding, bidder shall submit following documents: Reference list of previous supply for similar item, giving following detail: Name of the customer Specification of the item i.e., size and pressure & temperature rating. Service Quantity Year of supply Following test certificates shall be furnished alongwith shipment. Test certificate of chemical, mechanical testing. Manufacturers standard shop inspection & test report.
5.3 5.4.1
5.4.2
6.0 6.1 6.2 6.3 6.4 6.5
7.0 7.1 7.2 i) a) b) c) d) e) 7.3 i) ii)
iii)
The procedure and certificates to be submitted as per the requirement of clause 5.4 of this specification. GUARANTEE Manufacturer shall guarantee that the design, materials, manufacturing and testing of fittings comply with the requirement of this specification and applicable codes and standards. Manufacturer shall replace all the fittings which should result defective or fail during field pressure testing or fail to perform satisfactorily due to inadequate engineering, substandard material and workmanship. The manufacturer shall guarantee against any defect, failure or malfunctioning occurring during 12 months from the date of commissioning or 24 months from the date of supply whichever is earlier.
8.0 8.1
8.2
4405-PNMP-TS-0935
TECHNICAL SPECIFICATION FOR SS BALL VALVES FOR CNG REFILLING STATIONS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS PREPD
PRS/AS REVWD
AKS APPD
TABLE OF CONTENTS
1.0
SCOPE OF WORK
2.0
CODE & STANDARD
3.0
PRECEDENCE
4.0
DEVIATION
5.0
MATERIALS
6.0
DESIGN & MANUFACTURER
7.0
INSPECTION & TESTING
8.0
OTHER REQUIREMENTS
9.0
TEST REPORTS & CERTIFICATES
10.0
MARKING, PACKING & SHIPMENT
11.0
DOCUMENTATION
12.0
GUARANTEE
1.0
1.1
SCOPE OF WORK
The scope of this specification include design, manufacture/ supply, inspection/ testing/ marking / packaging/ handing and despatch of SS Ball Valves as per relevant codes. Purchaser 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.
1.2
2.0
CODES & STANDARD

Items Valve Applicable Codes and Standards MSS-SP-99
3.0
3.1
PRECEDENCE
In case of any conflict between this job specification and other document, the following order of precedence shall apply: Job Specification. International Standards/ Codes Applicable.
3.1.1 3.1.2
4.0
DEVIATION
Deviations if any required by Vendor shall be separately furnished against each clause giving reasoning for each deviation. Vendor to note that except the deviations furnished by them, Vendors offer shall be deemed to be in total conformity with the enquiry specifications
5.0
MATERIALS
5.1 The valve body shall be made out of material conforming to ASTM A479 Type 316. Material of construction of ball shall conform to ASTM A276 Type 316.
5.2
6.0
6.1
DESIGN & MANUFACTURE

All ball valves shall be designed in conformance with the requirement of ASME B31.3, MSS-SP-99 and other applicable code and standards. Area classification applicable for all item shall be Class-1, Division-1, Group-D as per NEC or Zone 1 Group-IIA/ IIB as per IS/ IEC specification or equivalent specification. All fittings shall be designed so that all parts/ components meet the requirements for the specified area classification. Valve shall be rated for a maximum working pressure of 5000 psig and shall be capable of operation between temperature ranges of -400F to 2500 F. Valve shall have PEEK seats with additional 1 set of nuts, back & front ferrule. Elastomeric seals, which require no packing adjustment, shall be used. Valve stem shall be of bottom loaded and blow out proof design. Ball shall be blow out proof and floating. Valves shall have positive handle stops, Nylon handle shall be provided. Handle shall indicate the direction to flow. In the case of three way valves the stem shall also provided a visual indication of flow direction if the handle is removed.
6.2
6.3 6.4 6.5 6.6 6.7
7.0
7.1
INSPECTION & TESTING

The valve manufacturer shall submit typical type test report for the following test carried out on similar valves:-
i)
Hydrostatic seat leak test shall be carried out with de-ionised water. There shall be no detectable set leakage at 1.1 times the rated pressure of the valve. Gas pressure test for seat and shell be carried out with nitrogen at 1000 psig. There shall be no detectable external leakage. Maximum allowable seat leakage shall be 0.1 atm-cc/min.
ii)
8.0
8.1
OTHER REQUIREMENTS
Manufacturer should confirm that valves are approved by Rail Road Commission of Texas, LP Gas Division under regulation for compressed natural gas or ANSI/ AGA NGV 3.1 1995, CAN/ CGA-12.3-M95 Fuel systems components for Natural Gas Powered Vehicle by Canadian Standard Association
8.2
Spares and Accessories
i)
If required, manufacturer shall furnish a list of recommended spares and accessories for valves required during start up and commissioning If required, manufacturer shall furnish a list of recommended spares and accessories required for two years of manual operation and maintenance of valves. Manufacturer shall quote for spares and accessories as per the material requisition.
ii)
iii)
9.0
9.1 9.2
TEST REPORTS & CERTIFICATES

The manufacturer shall supply material compliance certificates. The valve manufacturer shall provide test procedure and valve inspection and test report for type tests carried out on similar valves as per the requirements of clause 7.0
10.0
10.1 10.2
MARKING, PACKING & SHIPMENT

Heat code shall be marked on valve body to facilities tractability. All the items shall be suitably wrapped and packaged to with stand rough handing during ocean shipment and inland journey. Each item shall be properly tagged and package separately to facilitate easy identification. All items shall be wrapped and packaged in such-a- way that they can be preserved in original as new condition.
10.3
10.4
11.0
11.1 11.2
DOCUMENTATION
All documents shall be furnished in English language only. At the time of bidding, bidder shall submit following documents: i) a) b) c) d) e) Reference list of previous supply for similar item, giving following details: Name of the customer. Specification of them i.e., size and pressure & temperature rating. Service Quantity Year of supply
ii)
Test procedure and typical certificates to be submitted as per clause 5.3 and 5.4 of this specification. Copy of ISO: 9000 certification for supplier / manufacturer.
iii)
iv) v) vi) vii)
Manufacturer quantity control plan and sampling plan. Technical descriptive catalogue of manufacturer. General arrangement/ assembly drawing of valve showing all features. Sectional drawing showing major parts with reference number and material specification. Prior to shipment, manufacturer shall submit following test certificates and documents. Test certificate of chemical, mechanical testing. Manufacturers standard shop inspection test. Manufacturers standard shop inspection and test reports. The procedure and certificates to be submitted as per the requirements of clause 8.0 of this specification. Manual for installation, erection, maintenance and operating instructions including a list of recommended spares for valves.
11.3
i) ii) iii) iv)
v)
12.0 GUARANTEE
12.1 Manufacturer shall guarantee that the design, materials, manufacturing and testing of fittings comply with the requirement of this specification and applicable codes and standards. Manufacturer shall replace all fittings which would result defective or fail during field pressure testing or fail to perform satisfactorily due to inadequate engineering, substandard material and workmanship. 12.2 The manufacturer shall guarantee against any defect, failure or malfunctioning occurring during 12 months from the date of commissioning or 24 months from the date of supply whichever is earlier.
4405-PNMP-TS-0936
TECHNICAL SPECIFICATION FOR LAYING AND TESTING OF SS TUBES FOR CNG EQUIPMENT
0 18.02.09 REV REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS PREPD
PRS REVWD
AKS APPD
4405-PNMP-TS-0936
TABLE OF CONTENTS
1.0
SCOPE OF WORK & TECHNICAL SPECIFICATION
2.0
INSTALLATION PROCEDURE
3.0
REMAKE OF FITTINGS
4.0
REFERENCE SPECIFICATIONS, CODES AND STANDARDS
5.0
SCOPE OF SUUPLY
4405-PNMP-TS-0936
1.0 1.1
SCOPE OF WORK & TECHNICAL SPECIFICATION SCOPE OF WORK (FOR LAYING, TESTING & COMMISSIONING OF SS TUBING ): Laying, testing & commissioning of SS tubes and fittings complete with fixing arrangement with angle support by clamps. Supply of tubes, fittings and U-clamps (galvanized) shall be done by the contractor. Contractor shall engage subcontractor for this specialised work. The sub contractor should have to produce successful work completion certificate from any CNG companies like MGL, MNGL etc.
1.2
DETAILED SCOPE OF WORKS : Generally the following shall constitute the Contractors scope of work but not limited to as given herein: 1.2.1 Procurement of tubes, fittings and other requisite items from Client approved Vendors. Proper storing, stacking, identification, providing security and insurance during and before erection & commissioning. SS tubes shall be clamped to the MS Angle at every 1000 mm using U-clamps (galvanized) of any approved make. The practice of flattening tubes for clamping purpose shall not be permitted. MS Angle & U-clamps (galvanized) shall be isolated by rubber gaskets. Tubes shall be bend using tube benders only and any hot bending will be totally rejected. Tubes shall be cut using tube cutting device. Hot cutting is not allowed. Carrying out Hydrostatic/Pneumatic testing and purging with nitrogen to guarantee drying as per instructions given by Engineer-In-Charge (EIC) / OWNER; providing all tools, tackles, instruments, manpower and other related accessories for carrying out the testing of tubes. Start-up & commissioning assistance. Handing over the completed works to GAIL GAS for their operation/ use purposes. Any other work not specifically mentioned herein, but required for the satisfactory completion/ operation/ safety/ statutory/ maintenance of the works shall also be covered under the scope of work and has to be completed by the Contractor within specified schedule at no extra cost to GAIL GAS.
1.2.2
1.2.3 1.2.4
1.2.5
1.2.6 1.2.7
1.2.8
2.0 2.1
INSTALLATION PROCEDURE TUBE END PREPARATION 2.1.1 Cut the ends square with a hacksaw and a suitable guide. Tube cutters are satisfactory for most tube materials but tend to work harden stainless steel. As such proper care shall be exercised while cutting the SS tubes to avoid the hardening.
4405-PNMP-TS-0936
2.1.2 Burrs must be removed inside and outside for proper entry into fitting to prevent contamination and/ or restricted flow. Swagelok deburring tool shall be used. 2.1.3 2.2 Remove all fittings, chips, and grit before attachment of fittings.
ASSEMBLY 2.2.1 Tube line fabrication must be accurate so that the tube end easily enters the fitting in proper alignment. Do not force an improperly fitted tube line into the fittings. Ensure that the tube end is bottomed against the shoulder in the fitting body. This is necessary to prevent movement of the tube while the nut forces the ferrule to grip the tube and to seal through any imperfections that may exist on the outside tube surface. Never permit the fitting body to rotate during tube end make-up, use two wrenches. Assemble port connectors to components first and hold with a wrench while making up the tube joint. All types of union bodies must be held while each of the tube ends is made up. Never attempt to make up by torque. Always turn the nut the prescribed amount regardless of torque required. Fitting end plugs required only 1- turn from finger tight make up in all sizes. Any damaged valve and ferrule fittings should not be used and shall be rejected. No reuse of Valve & Ferrule fittings once tightened.
2.2.2
2.2.3
2.2.4 2.2.5
2.2.6
3.0 3.1
REMAKE OF FITTINGS A disassembled joint can be remade, simply by re-tightening the nut to the position of the original make up. For maximum number of remakes, mark the fitting and nut before disassembly. Before re-tightening, make sure the assembly has been inserted into the fitting until the ferrule(s) seats in the fitting. Retighten the nut by hand. Rotate the nut with a wrench to the original position as indicated by the previous marks lining up. (A noticeable increase in mechanical resistance will be felt indicating the ferrule is being re-sprung into sealing position.) Then snug the nut 1/12 turn (1/2 hex flat) past the original position. REFERENCE SPECIFICATION, CODES & STANDARDS The contractor shall carry out the work in accordance with this specification, ASME B 31.8 Gas Transmission and Distribution Piping Systems, Oil Industry Safety Directorate (OISD) norms. Should the contractor find any discrepancy, ambiguity or conflict in or between any of the standards and the contract documents, then this should be promptly referred to the Engineer-in-Charge (EIC) for his decision, which shall be considered binding on the contractor.
4.0
5.0
SCOPE OF SUPPLY
4405-PNMP-TS-0936
Unless otherwise specified, Contractor will procure from Client approved Vendors and supply all the tubes and fittings necessary to complete tubing for CNG commissioning. The Contractor shall not procure materials from any unauthorized Vendors other than GAIL GAS approved Vendors. In general the following tubes & fittings shall be procured by the Contractor: 1. 2. 3. 4. 5. 1 OD SS Tube of 0.109 wall thickness min. OD SS Tube of 0.095 wall thickness min. OD SS Tube of 0.065 wall thickness min. Double compression ferrule fittings of sizes 1, , , . SS Valves of suitable sizes.
The Contractor shall also supply all other materials and consumables as follows but not limited to:
1. Bolts and Nuts for supports, U-bolts with nuts, P-clamps for tubes etc., 2. All items not expressly mentioned in the contract but which are necessary for the satisfactory completion and performance of the work under this contract.
PIPING BOQ FOR METERING & MOTHER CNG STATION AT PANVEL
PIPING BILL OF MATERIAL FOR METERING & MOTHER CNG STATION AT PANVEL
4405-5511-0066 CNG-P 4405-5511-0066 CNG-P 4405-5511-0066 CNG-P DOCUMENT NO
1 0 P REV
22.01.09 23.12.08 12.12.08 REV DT
22.01.09 23.12.08 12.12.08 EFF DT
AM AM AM PREP D
DPS / AS DPS / AS DPS / AS REVWD
AKS AKS AKS APPD
1 OF 8 1 OF 7 1 OF 8 SHEET NO
ITEM NO.
ITEM
DESCRIPTION SIZE SPECN SCH/THK
MATERIAL
QTY. M/NOS
SPARE QTY.
STANDARD CODE TAG NO / FACE/RATING STD CODE
REMARKS
A. PIPE: 1. 2. 3. 4. 5. 6. PIPE PIPE PIPE PIPE PIPE PIPE DN DN DN 2 DN 4 DN 4 B24 D24 D 24 D 24 F 24 SCH 80 SCH 80 SCH 40 SCH 40 SCH 40 SCH 80 API-5L-Gr X42 SMLS API-5L-Gr X42 SMLS API-5L-Gr X42 SMLS API-5L-Gr X42 SMLS API-5L-Gr X42 SMLS API-5L-Gr X42 SMLS 3 3 35 30 200 3 1 1 5 5 40 1 ANSI B 36.10 ANSI B 36.10 ANSI B 36.10 ANSI B 36.10 ANSI B 36.10 ANSI B 36.10 PE / 150 # PE / 300 # BW / 300 # BW / 300 # BW / 600 # BW / 600 #
DN 18 F 24
B. VALVE: (a) BALL VALVE 1. 2. BALL VALVE BALL VALVE DN " D 24 DN 2" D 24 A 105 / AISI 316 A 216 Gr. 2 3 1 1 BAV 202 BAV 211 SW / 800 # RF / 300 #
4405-5511-0066 CNG-P DOCUMENT NO
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
2 OF 8 SHEET NO
All rights reserved
ITEM NO.
ITEM
MATERIAL
QTY. M/NOS
SPARE QTY.
REMARKS
3. 4. 5.
BALL VALVE BALL VALVE
DN 4 "
D 24
DN 18" F 24
WCB A 216 Gr. WCB A 216 Gr. WCB
2 1
1 1
BAV 211 BAV 222
RF / 300 # RF / 600 #
(b) GLOBE VALVE A 216 Gr. WCB / A 105 STELLITED
1.
GLOBE VALVE
DN 4
F 24
GLV 212
RF / 600 #
C. ELBOW (a) ELBOW 900 1. 2. ELBOW ELBOW DN " D 24 DN 2 " D 24 SCH 80 SCH 80 A 105 A 234 WPB 2 8 1 2 ASME B 16.11 ANSI B 16.9 SW / 3000 # BW / 300 #
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
3 OF 8 SHEET NO
All rights reserved
ITEM NO.
ITEM
MATERIAL
QTY. M/NOS
SPARE QTY.
STANDARD CODE TAG NO / FACE/RATING STD CODE ANSI B 16.9 ANSI B 16.9 BW / 300 # BW / 600 #
REMARKS
3. 4.
ELBOW ELBOW
DN 4 " DN 4 "
D 24 F 24
SCH 40 SCH 40
A 234 WPB A 234 WPB
4 8
2 2
(b) ELBOW 450 1. 2. 3. 4. D. TEE DN 4 x DN 2 SCH 40 x SCH 40 ANSI B 16.9 ELBOW ELBOW ELBOW ELBOW DN " D 24 DN 2 " DN 4 " DN 4" D 24 D 24 F 24 SCH 80 SCH 40 SCH 40 SCH 40 A 105 A 234 WPB A 234 WPB A 234 WPB 1 2 1 2 1 1 1 1 ASME B 16.11 ANSI B 16.9 ANSI B 16.9 ANSI B 16.9 SW / 3000 # BW / 300 # BW / 300 # BW / 600 #
1.
TEE
D 24
A 234 WPB
BW / 300 #
E. FLANGE :-
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
4 OF 8 SHEET NO
All rights reserved
ITEM NO.
ITEM
MATERIAL
QTY. M/NOS
SPARE QTY.
REMARKS
1. FLANGE 2. FLANGE 3. FLANGE 4. FLANGE F. BLIND FLANGE :1. 2. 3. 4. G. BLIND FLANGE BLIND FLANGE BLIND FLANGE BLIND FLANGE
DN 2" DN 4" DN 18" DN 4"
D 24 D 24 F 24 F 24
A 105 A 105 A 105 A 105
9 6 4 3
2 1 1 1
ANSI B 16.5 ANSI B 16.5 ANSI B 16.5 ANSI B 16.5
WNRF / 300 # WNRF / 300 # WNRF / 600 # WNRF / 600 #
DN 4" DN 2" DN 18 " DN 4"
D 24 D 24 F 24 F 24
A 105 A 105 A 105 A 105
2 3 1 1
1 1 1 1
ANSI B 16.5 ANSI B 16.5 ANSI B 16.5 ANSI B 16.5
RF / 300 # RF / 300 # RF / 600 # RF / 600 #
GASKETS
1.
GASKET
DN 2"
D 24
AISI 304 / ASBESTOS
10
API 601
SPIRAL WOUND / 300 #
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
5 OF 8 SHEET NO
All rights reserved
ITEM NO.
ITEM
MATERIAL
QTY. M/NOS
SPARE QTY.
STANDARD CODE TAG NO / FACE/RATING STD CODE API 601 API 600 API 600 SPIRAL WOUND / 300 # SPIRAL WOUND / 600 # SPIRAL WOUND / 600 #
REMARKS
2. 3. 4.
GASKET GASKET GASKET
DN 4" DN 4 "
D 24 F 24
AISI 304 / ASBESTOS AISI 304 / ASBESTOS AISI 304 / ASBESTOS
8 4 5
2 2 1
DN 18" F 24
H. STUD WITH TWO NUTS ANSI B18.2.2 HEAVY HEX ANSI B18.2.2 HEAVY HEX ANSI B18.2.2 HEAVY
1.
STUD WITH TWO NUTS
3/4 x L 90
D 24
A193-B7 / A 194-2H
96
16
ANSI B 16.5 / 300#
DN2
2.
STUD WITH TWO NUTS
3/4 x L 115 7/8 x L 145
D 24
A193-B7 / A 194-2H A193-B7 / A 194-2H
56
16
ANSI B 16.5 / 300# ANSI B 16.5 / 600#
DN4
3.
STUD WITH TWO NUTS
F 24
40
16
DN4
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
6 OF 8 SHEET NO
All rights reserved
ITEM NO.
ITEM
MATERIAL
QTY. M/NOS
SPARE QTY.
STANDARD CODE TAG NO / FACE/RATING STD CODE HEX
REMARKS
4.
STUD WITH TWO NUTS
1 1/4" x L 275
F 24
A193-B7 / A 194-2H
120
24
ANSI B18.2.2 HEAVY HEX
ANSI B 16.5
DN8
I. SOCKOLET 1. SOCKOLET DN " D 24 A 105 1 1 MSS SP 97 SW / 3000#
J. TUBES & ASSOCIATED FITTINGS 1. TUBE & FITTINGS 2. TUBE & FITTINGS 3. TUBE & FITTINGS K. WELDOLET 1 OD OD OD SS SS SS 0.109" 0.095" 0.065" TP-316 TP-316 TP-316 20 120 20 5 10 5 ASTM A269 ASTM A269 ASTM A269 REVISED REVISED REVISED
1.
WELDOLET
DN 18 " x DN 4
F 24
SCH 80 x SCH 40
A 105
MSS SP 97
BW/600#
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
7 OF 8 SHEET NO
All rights reserved
LINE SCHEDULE FOR IMPLEMENTATION OF CNG STATION AT PANVEL JOB NO. 4405
PROJECT:IMPLEMENTATION OF CNG STATION PLANT: IMPLIMENTATION OF CNG STATION AT

PANVEL
4405-5511-0090
18.02.09 18.02.09
PA
RB
AKG
1 of 3
SHEET NO
All rights reserved
LINE SCHEDULE
FORM NO: 02-0000-0021 F4 REV 0
DOCUMENT NO REV REV DT EFF DT PREPD REVWD
APPD
IDENTIFICATION
LOCATION NORMAL PRESS. TEMP . KG/CM2 oC G 63 28
CONDITION DESIGN TEMP.oC PRESS. Kg/cm2 MAX MIN g 92 50 10
SPECIFICATIO N TEST INS. PIPE PRESS. KG/CM2G CLASS CLASS 115 F24
DIA. MEDIU M INCH 18 NG
P&ID PIPE NUMBE R 019 4405-0000-0021
FROM
TO
4 4
NG NG
001 005
4405-0000-0021 4405-0000-0021
18 Existing Line from Metering Skid. 18-NG-019-F24 Metering Skid
To Flange For Future provision B/L OF METERING SKID 2NG-006-D24/ 2NG-007-D24/ 2NG-030-D24 VENT CNG Compressor CNG Compressor CNG Compressor SS TUBE PRIORITY PANEL PRIORITY PANEL CASCADE CASCADE CASCADE CASCADE
63 19
28 27
92 26
50 30
10 10
115 32.5
F24 D24
2 2 2 1 1 1 1/2 1/2 1/2
NG NG NG NG NG NG NG NG NG NG
020 006 007 030 028 029 031 033 034 035
4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021
4-NG-005-D24 4-NG-005-D24 4-NG-005-D24 4-NG-005-D24 CNG Compressor CNG Compressor PRIORITY PANEL PRIORITY PANEL PRIORITY PANEL PRIORITY PANEL
3 19 19 19 250-255 250-255 250-255 250-255 250-255 250-255
25 27 27 27 50 50 50 50 50 50
9 26 26 26 280 280 280 280 280 280
30 30 30 30 70 70 70 70 70 70
10 10 10 10 10 10 10 10 10 10
11 32.5 32.5 32.5
B24 D24 D24 D24

PANVEL
4405-5511-0090
18.02.09 18.02.09
PA
RB
AKG
2 of 3
SHEET NO
All rights reserved
LINE SCHEDULE
FORM NO: 02-0000-0021 F4 REV 0
APPD
3/4 3/4 3/4 3/4
NG NG NG NG
032 036 037 033
4405-0000-0021 4405-0000-0021 4405-0000-0021 4405-0000-0021
CASCADE CASCADE CASCADE PRIORITY PANEL PRIORITY PANEL PRIORITY PANEL
3/4
NG
038
4405-0000-0021
3/4
NG
039
4405-0000-0021
NG-039-SS TUBE NG-033-SS TUBE NG-038-SS TUBE FLEXIBLE HOSE/MOBILE CASCADE FLEXIBLE HOSE/MOBILE CASCADE FLEXIBLE HOSE/MOBILE CASCADE
250-255 250-255 250-255 250-255
50 50 50 50
280 280 280 280
70 70 70 70
10 10 10 10
250-255
50
280
70
10
250-255
50
280
70
10

PANVEL
4405-5511-0090
18.02.09 18.02.09
PA
RB
AKG
3 of 3
SHEET NO
All rights reserved
LINE SCHEDULE
FORM NO: 02-0000-0021 F4 REV 0
APPD
ITEM NO.
ITEM
MATERIAL
QTY. M/NOS
SPARE QTY.
REMARKS
L. INSULATION JOINT 1. INSULATION JOINT * DN 4 2 1

HOLD (ELECTRICAL
) M. CONDUCTIVE CORE THERMOPLASTIC HOSE
1.
CONDUCTIVE CORE THERMOPLASTIC HOSE (SS-316 Tube Adapter End Connection & Spring Guard x 5 ft. Long.)
3/8 OD Both SS Side
TP-316
NFPA 52, AGA1-93 & AGA/CGA, ANSI 4.2112.52
REVISED
NOTE: - 1) DN 3/4 GATE VALVE, DN 3/4 CHECK VALVE 3/4 PLUGS &1/2 PLUG ARE IN VENDOR SCOPE.
2) CNG COMPRESSORES FLANGES ARE IN VENDOR SCOPE. 3) REVISION 1 BOQ REVISED DUE TO CLIENT COMMENTS ON SS TUBE AND FITTINGS.
1 REV
22.01.09 REV DT
22.01.09 EFF DT
AM PREPD
DPS / AS REVWD
AKS APPD
8 OF 8 SHEET NO
All rights reserved
23
22
21
20
19
18
17
16
15
14
13
12
11
10
PLANT NORTH
L
ACTUAL NORTH
26 .8
AGRICULTURAL LAND
Na
la
OPEN FIELD
Drain
K
To we r
High tens ion Line (6 l ine
g Hi
ht
en
si
on
s, 1 32
kv)
BOUNDARY WALL
Office Building
0M R10
31000
23400
FENCING
tens
ion
LINE NO.0931-NG-18-6CI-N
s, 1 32 k v)
P TA
F OF
IN PO
19400
Line
(6 l ine
4 m Wide Concret Road
High
28356
29040
4"-NG-001-F24
EP
TAG NO.80-PL-00-101
Gu
d ar
Ro Tr
om s r fo
me
(2
) kv
(a) E =306559.399 N =2098272.641

HU T
an
Electric Line
8576
30"-P-80-2410-DIA
OPEN FIELD
Bench Mark E =306484.400 N =2098289.500 Z =14.751

Gr ou nd
y la
TAG NO.18"P-80-2401-DIA
LINE NO.0910-NG-10-6CI-N LINE NO.0915-NG-10-6CI-N
TAG NO.10"-BD-80-2403-DIA
OPEN FIELD
TAG NO.80-KL/MR-00-101
LINE NO.09A-NG-9-6CI-N
h tc Di
EP EP
N E
14000
EP
WATER TANK UNDER GROUND
19750
BOUNDARY WALL DRAIN
FENCING
KEY PLAN
NOTE:1. ALL FACILITIES COMING IN 100M RADIUS HAS BEEN SHOWN IN KEY PLAN DRAWING. 2. THE AREA SHOWN IN HATCHED LINE IS HAZARDEOUS AREA.
23400
E
300 (TYP.) 4500 2000 5000
TAG NO.Y-109
4 m Wide Concret Road
19400
TOILET
2080
4000
G
LINE NO.0929-NG-24-6CI-N LINE NO.0931-NG-18-6CI-N
ELECTRICAL PANEL (LT)

5000
2000
TA
OF
PO
IN
8035
Fi
4175
4"-NG-001-F24
EP EP
29040
FGL 0.000(14.000 MSL)
3000
re
Hy
a dr
nt
5350
V N G S F P
S N F G
CASCADE
1400
6500
4000
2000
3400 7100
COMPRESSOR
6000
Of
fi
ce
Bu
1200
il
n di
3000
1000
D.G.SET
5100 3000
1000
3000
BL
N
3500
STANDBY COMPRESSOR
V N G S F
5000 3000
EP
EP
EP
EP
LOADING PLATFORM FOR LCV MOBILE
GAS TRENCH
METERING SKID
E
3000
NOTES
1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.
EP
11266
EP
a Gu
rd
E
om Ro a Tr ns
r fo
r me
22
kv
)
N 4"-
(a) E =306559.399 N =2098272.641
2. FGL OF THE PROPOSED CNG STATION HAS BEEN ASSUMED AS O.OOOM LEVEL WHICH CORRESPONDS TO 14.000M ABOVE MSL. 3. EQUIPMENT SIZES ARE TENTATIVE AND INDICATIVE ONLY. 4. 4" PIPE LINE (LINE NO. 4"-NG-001-F24) WILL BE TAPPED FROM 18" EXISTING PIPELINE (LINE NO. N0931-NG-18-6CI-N).
F
G-0
01-
F24
MM 0x6
GI
EA
STR RTH
IP
T U H
5. CNG GAS STORAGE & FILLING WILL BE CONNECTED BY SS TUBE. 6. THE PROPOSED CNG FACILITIES ARE DESIGNED IN ACCORDANCE WITH THE FOLLOWING CODE & GUIDELINES. (a). NZS 5425-1980 (b). PETROLEUM RULES-2002 (c). GAS CYLINDER RULES-2004 (d). GUIDELINES OF CHIEF CONTROLLER OF EXPLOSIVE NAGPUR. 7. COMPRESSOR WILL BE HOUSED IN WEATHER PROOF ENCLOSURE. NO SEPERATE SHED FOR CNG COMPRESSOR WILL BE PROVIDED. 8. CASCADE WILL BE PROVIDED AT ABOVE COMPRESSOR NO SEPERATE SHED WILL BE PROVIDED FOR CNG CASCADE 9. HAZARDOUS AREA IS SHOWN BY HATCHING LINE. 10. LIGHTING FIXTURES PROVIDED ON THE FENCE OF CNG COMPRESSOR AREA SHALL BE FLP (EX `d`) TYPE CONFORMING TO ENCLOSURE GROUP IIA/IIB & TEMP. CLASS T6. 11. ALL OTHER LIGHTING FIXTURES AND ELECTRICAL EQUIPMENT SHALL BE NON EXPLOSION PROOF DUE TO THEIR LOCATION IN SAFE AREA. 12. AIR COMPRESSOR MOTOR FOR CNG COMPRESSOR SHALL BE 7.5KW,FLP (EX`d`) TYPE CONFORMING TO ENCLOSURE GROUP IIA/IIB & TEMP. CLASS T6. 13. IN GENERAL, ALL FIELD MOUNTED ELECTRONIC INSTRUMENTS SHALL BE PROVIDED WITH IP-65 WEATHER PROOF AND DUST PROOF ENCLOSURES IN ACCORDANCE WITH IEC 529 NOTATION/IS 2147 AND SHALL BE INTRINSICALLY SAFE/ FLAME PROOF.
D
INGRESS
EGRESS
Bench Mark E =306484.400 N =2098289.500 Z =14.751
LEGEND
O O S BL EP N V F G P DCP 10Kg. FIRE EXTINGUISHER DCP 75Kg. FIRE EXTINGUISHER CO 2 4.5Kg. EXTINGUISHER 8 2 4 4 NOS. NOS. NOS. SET.
Play Ground
SAND BUCKET (4 NOS. EACH SET)
E N
BORE WELL 1 NOS. EARTH PIT 12 NOS. NO SMOKING SIGN 3 NOS. STOP VEHICLE SIGN 2 NOS. NO OPEN FLAME PERMITTED SIGN 3 NOS. FLAMMABLE GAS SIGN 3 NOS. SIGN SHOWNING DETAILED PRECAUTION & PROCEDURE OF LCV FILLING 1 NOS. LIGHTING INSIDE COMPRESSOR AREA 8 NOS. STREET LIGHTS 11 NOS. FLOOD LIGHTS 6 NOS. EQUIPMENT EARTH PITS 6 NOS. NEUTRAL EARTH PITS 2 NOS.
1 0
13.01.09 19.12.08 DATE
GAIL GAS COMMENTS INCORPORATED FOR CCOE APPROVAL ISSUED FOR CCOE APPROVAL DESCRIPTION
Y.K. Y.K. PPD.
Y.P./P.R.S. Y.P./P.R.S. CKD.
A.K.S. A.K.S. APPD.
REV.
LIST OF EQUIPMENTS
S.NO.
1. 2. 3. 4.
A
PROJECT:-
CNG DISTRIBUTION
REV. 0 1 1 OF 1
EQUIPMENT
COMPRESSOR STANDBY COMPRESSOR (FOR FUTURE PROVISION) DG SET METERING SKID STORAGE CASCADE (STATIONARY) MOBILE CASCADE
NOS.
1. 1. 1. 1. 1. 1.
SERVICE
CNG CNG EMERGENCY POWER CNG CNG CNG
BLOCK SIZE
(L.W.H.-IN MTRS.)
CLIENT:
CAPACITY/RATING
1200 SCMH -------35 KVA 4500 WLC 3000 WLC PERMISSIBLE COVERED AREA ON GROUND PROPOSED COVERED AREA ON GROUND = =
FOLLOWING SAFETY FEATURES SHALL BE PROVIDED. AREA

TOTAL FENCED AREA OF PLOT = 23.4M x 19.4M 453.96 SQUARE METRES 20% OF PLOT AREA 90.79 SQUARE METRES 90.42 SQUARE METRES
2 1. 2 NOS. 45Kg CO FLOODING SYSTEM. (EACH COMPRESSOR) 2. 2 NOS. LEL DETECTORS IN EACH COMPRESSOR. 3. 2 NOS. UV FLAME DETECTORS IN EACH COMPRESSOR.
GAIL GAS LIMITED

NEW DELHI- NOIDA
TITLE:
SHEET
6.5x4.5x4.0 -------3.0x1.2x1.5 5.0x2.0x2.0 6.0x2.0x1.6 3.82x1.8x1.5
SCALE: 1: 500,1000 A1 DRG. NO.
PROPOSED PLAN OF CNG COMPRESSION STATION FOR CCOE APPROVAL. COMPRESSION STATION, PANVEL
4405-1000-0001 FILE: 4405-1000-0001_REV 1
5. 6.
REMARK:ALL EQUIPMENTS ARE PROVIDED WITH CO

2
& DCP FIRE EXTINGUISHER.
PROJECTS & DEVELOPMENT INDIA LTD. NOIDA

6 5 4 3 2 1
23
22
21
20
19
18
17
16
15
14
13
12
11
10
LP
4405PNCN-TS-0601
SPECIFICATION FOR PIPING FABRICATION AND ERECTION
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
SNPG
GC
PCC
PREPD
REVWD APPD
4405PNCN-TS-0601
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 GENERAL CODES OF PRACTICE FABRICATION WELDING ERECTION INSPECTION PROTECTIVE COATING FLUSHING HYDROSTATIC TESTING
4405PNCN-TS-0601
SPECIFICATION FOR PIPING FABRICATION AND ERECTION 1.0 GENERAL
This specification covers the minimum technical requirements for the fabrication, erection and testing of piping systems in accordance with the requirements of this specification, approved drawings and as directed by COMPANY. 2.0 2.1 CODES OF PRACTICE All phases of work pertaining to process lines handling Natural Gas shall be carried out if accordance with latest edition of ANSI B 31.8 "GAS TRANSMISSION AND DISTRIBUTION PIPING SYSTEM" with modifications and additions as specified in various sections of this specification. All phases of work pertaining to utility lines shall be carried out in accordance with the latest edition of ANSI 8 31.3 "CODE FOR PRESSURE PIPING, PETROLEUM REFINERY PIPING" CONTRACTOR shall bear the cost of repair, modifications and replacements, if any, becoming necessary due to noncompliance of codes, this specification or due to disregard of COMPANY's instructions. FABRICATION All fabrication shall be carried out in accordance with piping general arrangement drawings, (prepared by CONTRACTOR and approved by COMP ANY) including this specification and codes as specified in section 2.0. CONTRACTOR shall be responsible for working to the exact dimensions as per the approved drawings. Dimensional tolerances to be adopted during implementation of fabrication work shall be as per attached sketch "TOLERANCES FOR FABRICATION" Flange bolt holes shall generally straddle the established centre lines unless other orientation is required and as called out if approved drawings. Threading shall be NPT to ANSI B 1.20.1. Threading shall preferably be done after bending, forging or heat treatment operation. However if it is not possible, precaution shall be taken to protect threading against deformation. Thread shall be clean cut with no burrs or stripping. Dies shall be new, sharp and properly designed for piping material. Ends shall be reamed to remove burrs. All threaded joints shall be aligned properly. The pipe entering unions shall be due to centerlines so as to avoid forcing of union coupling during make up. Damaged threads shall be cut from the end of run and the pipe shall be rethreaded. Immediately before testing the piping, all threads of pipe and fittings shall be thoroughly cleared of cuttings, fuel oil or other foreign matter. The male threads shall be sealed with thread sealant and the piping made up sufficiently for the thread to seize. Sealant shall be Teflon tape. Seal welding of threaded connections when specified shall include the first block valve, cover all "threads. The joint shall be cleaned of all cutting oil and other foreign material and made up
2.2
3.0 3.1
3.2
3.3
3.4
3.5
3.6
3.7
4405PNCN-TS-0601
dry to full thread engagement. Instrument threaded connections which are frequently subjected to testing and maintenance shall not be seal welded 3.8 All threaded connections shall be protected from rusting by applying greases or oil when in operating condition. When socket weld fittings or valves are used, pipe shall be spaced I approximately 1/16" to avoid bottoming which could result in excessive weld stress. Where the ends of the piping components being welded have an internal surface misalignment exceeding 1.6mm, the wall of the component extending internally shall be trimmed by machining so that the adjoining internal surface will approximately flush. Laying, Cutting and Fitting up Extensive use of templates, gauges, plumb lines shall be made for laying, cutting and fitting up of various piping components for fabrication. 3.12 Pipe joints shall be accomplished by butt welding for pipe sizes 2" and above by screwed coupling for pipes 1 1/2" and below with the exception for utilities piping which shall have socket weld coupling for size upto 1 1/2". Edge preparation for butt weld joints shall conform to ANSI B16.25. Cutting of edges shall preferably be done by machine. Pipe bends for piping system below 1 1/2" NB shall be used when called for in approved arrangement drawing. Cold bending will be implemented with special bending tools with guides to avoid flattening. The minimum radius allowed shall not be less than five times the outside diameter of pipe. CONTRACTOR shall obtain COMPANY's approval of bending tool to be used. All branch connection shall be joined to header with full penetration weld. Reinforcement pads where required shall be added only after external and internal visual inspection of the attachment. Re-enforcement pad shall be provided with tapped weep hole. Weep holes shall be plugged. On completion of both shop and field fabrication, all sub-assemblies shall be cleaned from the inside and outside by suitable mechanical means ensuring that they are free from all loose foreign materials such as scales, sand, weld spatters, oil, grease, cutting chips etc. WELDING Welding of pipelines shall be done as per applicable codes and Annexure-1 5.0 5.1 ERECTION Pre-fabrication and Field Assembly Extent of pre-fabrication shall be purely at the discretion of CONTRACTOR keeping in view following:
3.9
3.10
3.11
3.13
3.14
3.15
3.16
4.0
4405PNCN-TS-0601
SPECIFICATION FOR PIPING FABRICATION AND ERECTION 5.1.1
Field joint shall be decided by CONTRACTOR keeping in view the transportation of pre fabricated pieces to site. There can be some variations in the dimensions and level appearing in the arrangement drawings and those actually occurring at site due to minor variations in the location of equipments, structures, cut out etc. Adequate field joints shall be provided, permitting assembly and erection of pipe work without major modification. Supporting Location and design of pipe supports shown in approved drawings and support drawings shall be strictly followed.
5.1.2
5.2
5.2.1 5.2.2
Supports shall be installed in such a way that they do not contribute to over stressing of a line. Fabrication and erection of additional supporting elements and structural fixtures which in COMPANY's view are required for proper supporting of the system, shall be carried out by CONTRACTOR at no extra cost. All temporary supports, elements required for alignment, erection and assembly shall be removed after completion of work. Equipment hook-up Prior to hook-up, the alignment and trueness of flange faces shall be checked to ensure that no undue stresses shall be induced in the system while hooking up. INSPECTION CONTRACTOR shall provide all facilities/assistance to COMPANY for proper execution of their inspection without any extra charge. All piping work shall be subjected to inspection by COMPANY at any time during fabrication. CONTRACTOR shall furnish to COMPANY detailed work programme sufficiently in advance, in order to enable COMPANY to arrange for inspection. PROTECTIVE COATING All above ground piping system shall be applied with protective coating in accordance with specification for shop & field painting. All underground portion of piping system shall be coated with three layer P.E. coaling. CONTRACTOR shall prepared procedure for epoxy painting of buried pipeline for approval of COMPANY. Procedure shall include surface preparation, brand and type of coaling to be adopted. Coating of pipes shall not commence without approval of coating procedure. Total dry film thickness to be achieved shall not be less than 300 microns. Compatible primer and finish coat as recommended by coating manufacturer shall only be applied. Coating integrity shall be checked by "Holiday detector" over full length of coated pipe work. Coaling to be supplied by CONTRACTOR shall be suitable for design temperature.
5.2.3
5.3 5.3.1
6.0 6.1
6.2
7.0 7.1
7.2
4405PNCN-TS-0601
SPECIFICATION FOR PIPING FABRICATION AND ERECTION 7.3
Once the coating has been accepted by COMPANY, backfilling operation can be started. In order to protect coated pipe from damage, the excavated trench shall be examined for stone, rock and any other hard substance detrimental to coating. All such substances shall be removed before lowering the pipe in the trench. COMPANY may ask for a 100mm padding of clear sand under and above pipeline in rocky or otherwise hard soil area. No additional payment on account of padding shall however be admissible. FLUSHING Completed piping systems shall be flushed by CONTRACTOR with fresh water, to clean the pipe of all dirt, debris, and foreign material. CONTRACTOR shall prepare a procedure for flushing of the system for approval of COMPANY. j Flushing shall not be commenced without approval of flushing procedure.
8.0
8.1
CONTRACTOR shall perform all activities like' dismantling and reinstalling of all strainers. in line instruments etc. before and after completion of flushing. Flushing shall be considered as complete only after inspection and approval by COMPANY. Disposal of muck and flushing media shall be arranged by CONTRACTOR as directed by COMPANY, in such a manner that it does not spoil the adjacent installation. CONTRACTOR shall obtain COMPANY approval regarding the place and method to be adopted for disposal of debris. Record of flushing giving following details shall be submitted by CONTRACTOR to COMPANY for its approval and records: a) b) Date of flushing Identification of line : flushed-line number
8.2 8.3
8.4
9.0 9.1
HYDROSTATIC TESTING Completed piping system as approved by COMPANY shall be hydrostatically tested in the presence of COMPANY. The general requirements of hydrostatic testing shall be in accordance with codes specified in section 2.0. CONTRACTOR shall prepare hydrostatic test procedure based on specified codes. The hydrostatic test shall commence only after approval of procedure by COMPANY. Piping system shall be hydrostatically tested to a pressure corresponding to 1.4 times the design pressure. Fresh water shall be used as test media. CONTRACTOR shall locate the source of water supply and arrange for transportation of water to test site. CONTRACTOR shall arrange at his own cost the water analysis and confirm that water is suitable for testing. In case any corrosion inhibitor is to added, the same shall be done after approval of COMPANY. Lines repaired subsequent to hydrostatic test shall be retested using the same procedure as
9.2
9.3
9.4
9.5
4405PNCN-TS-0601
originally adopted. However COMPANY may waive such retest in case of minor repairs by taking precautionary measures to ensure sound construction. 9.6 All equipment and instruments used for hydrostatic test shall be approved by COMPANY before start of tests. Pressure gauges shall be installed on line to measure test pressures. In case of longer lines two or more pressure gauges shall be installed as directed by COMPANY. One gauge shall be installed at the discharge of the pressurising pump. Pressure gauge used for hydrostatic testing shall be calibrated with dead weight tester in the presence of Engineer-in-charge. Range of pressure gauge shall generally be 1.5 times the test pressure. Orifice plates and restriction orifices shall not be installed until hydrostatic testing is completed. Temporary gaskets shall be used during testing. First block valve of pressure instruments shall be half open & plugged at the time of hydrostatic testing. Temperature connections shall be blanked off during testing.
9.7
9.8
9.9
9.10 All equipments, in line instruments, relief valves shall be disconnected from piping system by means of blinds during testing. Control valves shall be replaced by spool pieces during testing. 9.11 High point vents and low point .drain required for testing in addition to those marked in the drawings shall be provided by CONTRACTOR at his own cost. 9.1.2 9.1.3 All welded and screwed joints shall be kept clean for detecting leaks during testing. Test pressure shall be maintained long enough to facilitate complete inspection of the system. Minimum duration of test shall be 6 hours unless otherwise specified. Pressurising equipment shall be isolated immediately after test pressure is attained. After successful completion of hydrostatic testing, the piping system shall be dewatered. All lines shall be completely dried using compressed air. CONTRACTOR shall make his own arrangement for supply of compressed air. Drying of lines shall be considered complete on approval by COMPANY. Test Records The records in duplicate shall be prepared and submitted by CONTRACTOR as below: a) b) c) d) e) f) Date of test Identification of pipe tested - line number Test pressure Test results Signature of CONTRACTOR Approval signature by COMPANY
9.14
9.15
4405PNCN-TS-602
SPECIFICATION FOR HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
SNPG
GC
PCC
PREPD
REVWD
APPD
4405E- 602
CONTENTS
1.0 2.0 3.0 4.0
SCOPE REFERENCE DOCUMENTS HEALTH, SAFETY AND ENVIRONMENT (HSE) REQUIREMENT DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR 6- 7
ANNEXURES 1. 2. 3. ANNEXURE A ANNEXURE -B ANNEXURE -C RELEVANT I.S. CODES REPORTING FORMATS 5 NOS. DOs & DONTS ABOUT SAFETY ASPECTS AS PER FACTORIES ACT
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
1.0
SCOPE This specification establishes the Healthy, Safety and Environment (HSE) management requirement to be compiled with by the Contractors during construction. Requirement stipulated in this specification shall supplement the requirement of HSE management given in relevant Act (S)/ legislations. General Condition of Contract (GCC) Special Condition of Contract (SCC) and Job Specifications. Where different documents stipulate different requirement the most stringent shall be adopted.
2.0
REFERENCES This document should be read in conjunction with following: General Conditions of Contract (GCC) Special Conditions of Contract (SCC) Job Specifications Relevant IS Codes (refer Annexure-A) Reporting Formats (refer Annexure-B)
3.0
REQUIREMENT OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT SYSTEM TO BE COMPLETED BYBIDDERS. Management Responsibility The Contract should have a document HSE policy to cover commitment of the organization to ensure health, safety and environment aspects in their line of operations The HSE management system of the Contractor shall cover HSE requirement including but not limited to what specified under clause 1.0 & 2.0 mentioned above Contractor shall be fully responsible for planning and implementing HSE requirement to the satisfaction of the company. Contractor as a minimum requirement shall designate/deploy the following to co-ordinate the above: No. Of workers deployed Up to 250 -
3.1 3.1.1
3.1.2
3.1.3
Designate one safety supervisor who will guide the workers from time to time, as well as impart training basic guidelines at least weakly once. Deploy one qualified and experienced safety Engineer/ Officer who will guide the workers from time to time as well as impart basic guideline & training at least weakly once. One additional safety engineer/Officer (for every 500 or less) whose function will be as mentioned above
All rights reserved
Above 250 & upto 500 -
Above 500
FORM NO: 02-0000-0021F2 REV1
4405E- 602
Contractor shall indemnify and hold harmless GGL/PDIL & their representatives from any and all liabilities arising out of non fulfillment of HSE requirements. 3.1.4 The Contractor shall ensure that the Health, Safety and Environment (HSE) requirements are clearly understood & faithfully implemented at all levels, at each and every site/ work place. The Contractor shall promote and develop consciousness for Healthy, Safety and Environment among all personnel working for the Contractor. Regular awareness programs and fabrication shop/work site meeting shall be arranged on HSE activities to cover hazards involved in various operations during construction. Arrange suitable first aid measures such as First Aid Box, trained personnel to give First Aid, Stand by Ambulance or Vehicle and install fire protection measures such as: adequate number of steel buckets with sand and water and adequate fire extinguishers to the satisfaction of GGL/PDIL. The Contractor shall evolve a comprehensive planned and documented system for implementation and monitoring of the HSE requirements. This shall submitted to GGL/PDIL for approval well in advance, prior to start of work. The monitoring for implementation shall be done by regular inspection and compliance to the observations thereof. The Contractor shall get similar HSE requirements implemented at his sub-contractor (s) work site/ Office. However, compliance of HSE requirement shall be the sole responsibility of the Contractor. Any review/ approval by GGL/PDIL shall not absolve the Contractor of his responsibility/ liability in relation to all HSE requirements. Non-Conformance on HSE by the Contractor (including his Subcontractors) as brought out during review/ audit by PDIL/ OWNER representative shall be resolved forthwith by Contractor. Compliance report shall be possibility submitted to PDIL/GGL at the earliest. The Contractor shall ensure participation of his Resident Engineer/Site-in-Charge in the Safety Committee/HSE Committee meetings arranged by GGL/PDIL. The compliance of any observation shall be arranged urgently. Contractor shall assist GGL/PDIL to achieve the targets set by them on HSE during the project implementation.
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10 The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-compliance or continuous failure in implementation of any of HSE provisions; GGL/PDILmay impose stoppage of work without any Cost & Time implication to Owner and/or impose a suitable penalty for non-compliance with a notice of suitable period, upto a cumulative limit of 1.0% (one percent) of Contract value with a ceiling of Rs. 10 lakhs.This penalty shall be in addition to all other penalties specified elsewhere in the contract. The decision of imposing stoppage of work, its extent & monitory penalty shall rest with GGL/PDIL & binding on the Contractor. 3.1.11 All fatal accidents and other personnel accidents shall be investigated by a team of Contractors senior personnel for root cause and recommend corrective and preventive actions. Findings shall documented and suitable actions taken to avoid recurrences shall be communicated to GGL/PDIL.GGL/PDIL shall have the liberty to independently investigate such occurrences and Contractor shall extend all necessary help and co-operation in this regard. 3.2 House Keeping
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
3.2.1
Contractor shall ensure that a high degree of house keeping is maintained and shall ensure the followings: All surplus earth and debris are removed/disposed off from the working site to identified location (s). Unused/Surplus Cables Steel items and steel scrap lying scattered at different places within the working areas are removed to identified location (s). All wooden scrap, empty wooden cable drums and other combustible packing materials shall be removed from work place to identified location(s). Roads shall be kept clear and materials like pipes, steel,sand, boulders, concrete chips and bricks, etc. shall not be allowed in the roads to obstructs free movement of men & achineries. Fabricated steel structurals, pipes & piping materials shall be stacked properly for erection. Water logging on rods shall not be allowed. No parking of trucks/ trolleys, cranes and trailors etc.shall be allowed on of roads, which may obstruct the traffic movements. Utmost care shall be taken to ensure over all cleanliness and proper up keep of the working areas. Trucks carrying sand, earth and pulverized materials etc.shall be covered while moving within the plant areas. Healthy, Safety and Environment The Contractor shall provide safe means of access to any working place including provision of suitable and sufficient scaffolding at various stages during all operations of the work for the safety of his workmen, and GGL/ PDIL. Contractor shall ensure deployment of appropriate equipment and appliances for adequate safety and health of the workmen and protection of surrounding areas. The Contractor shall ensure that all their staff workers including their sub-Contractor (s) shall wear Safety Helmet and Safety shoes. Contractor shall also ensure use of safety belt, protective goggles, gloves etc. by the personnel as per jobs requirements. All these gadgets shall conform to relevant IS specification equivalent. Contractor shall ensure that a proper Safety Net System shall be used at appropriate locations. The safety net shall be located not more than 30 feet (9.0 metrs) below the working surface at site to arrest or to reduce the consequences of possible fall of persons working at different heights. Contractor shall ensure that flash back arrester shall used while using gas Cylinders at site. Cylinders shall be mounted on trolleys. The Contractor shall assign to his workmen, tasks commensurate with their qualification, experience and state of health for driving of vehicles, handling and erections of materials and equipments. All lifting equipments shall be tested certified for its capacity before use.
All rights reserved
a.
b.
c.
d.
e. f. g.
h.
i.
3.3 a)
b)
c)
d)
e)
FORM NO: 02-0000-0021F2 REV1
4405E- 602
Adequate and suitable lighting at every work place and approach there to shall be provided by the contractor before starting the actual work/ operation at night.. f) Hazardous and/or toxic material such as solvent coating or thinners shall be stored in appropriate containers. All hazardous materials shall be labeled with the name of the materials, the hazards associated with its use and necessary precautions to be taken. Contractor shall ensure that during the performance of the work all hazards to the health of personnel have been identified assessed and eliminated. Chemical spills shall be contained & cleaned up immediately to prevent further contamination. All personnel exposed to physical agents such as ionizing or nonionizing radiation ultraviolet rays or similar other physical agents shall be provided with adequate shielding or protection commensurate with type of exposure involved. Where contract or exposure of hazardous materials could exceed limits or could otherwise have harmful effects, appropriate personal protective equipments such as gloves, goggles, aprons, chemical resistant clothing and respirator shall be used Contractor shall ensure the following facilities at work sites: I) II) A Crche where 10 or more female Reasonable Canteen facilities are made available at appropriate location depending upon site conditions.
g)
h)
i)
j)
k)
l)
m)
Suitable facilities for toilet, drinking water, proper lighting shall be provided at site and labor camps, commensurate with applicable Laws/Legislation. Contractor shall ensure storage and utilization methodology of material that are not detrimental to the environment. Wherever required Contractor shall ensure that only the environment friendly material are selected. All person deployed at site shall be knowledgeable of and comply with the environmental laws, rules & regulation relating to the hazardous materials substance and wastes. Contractor shall not dump, release or otherwise discharge or dispose off any such materials without the authorization of GGL/PDIL. DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR On Awards of Contract The Contractor shall prior to start of work submit his Health. Safety and Environment Manual of procedure and HSE Plans for approval by GGL/PDIL. The Contractor shall participate in the pre-start meeting with GGL/PDIL to finalize HSE plans including the following. Job procedure to be followed by Contractor for activities covering Handling of equipments, Scaffolding, Electric Installation, describing the risks involved, actions to be taken and methodology for monitoring each. Organizations structure along with responsibility and authority records/ reports etc. on HSE activities.
n)
o)
4.0 4.1
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
4.2 4.2.1
During job execution Implement approved Health, Safety and Environment management procedure including but not limited to as brought our under para 3.0.Contractor shall also ensure to: Arrange workmen compensation insurance, registration under ESI Act, third party liability insurance etc. as applicable. Arrange all HSE permits before start of activities (as applicable) liken her work, confined space, work at heights, storage of Chemicals/explosives materials and its use and implement all precautions mentioned therein Submit timely the completed check list on HSE activities, Monthly HSE report, accident report, investigation report,etc. as per GGL/PDIL requirements. Compliance of instructions on HSE shall be done by Contractor and informed urgently to GGL/PDIL. Ensure that resident Engineers/Site-In-Charge of the Contractor shall amend the entire Safety Committee/HSE meeting arranged by GGL/PDIL only in case of his absence from site, a seconds senior most person shall be nominated by him in advance and communicated to GGL/PDIL. Display at site office and work locations caution boards,list of hospitals for emergency services available. Provided posters, banners, for safe working to promote safety consciousness Carryout audits/inspection at sub Contractor work as per approved HSE documents & submit the reports for GGL/PDIL review. Assistk in HSE audits by GGL/PDIL and submit compliance report. Generate & submit HSE records/ reports as per HSE Plan. Appraise GGL/PDIL on HSE activities at site.
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
ANNEXURE-A
RELEVANT IS-CODES FOR PERSONNEL PROTECTION IS: 2925-1984 IS: 4770-1968 IS: 6994-1973 (Part-I) IS: 1989-1986 (Part-I & III) IS: 3738-1975 IS: 5557-1969 IS: 6519-1971 : : : : : : : Industrial Safety Helmets. Rubber gloves for electrical purposes Industrial Safety Gloves (Leather & Cotton) Leather safety boots and shoes. Rubber knee boots Industrial and Safety rubber knee boots. Code of practice for selection, care and repair of Safety footwear Leather Safety footwear having direct moulding sole. Eye protectors. Ear protectors. Industrial Safety belts and harness.
IS: 11226-1985
IS: 5983-1978 IS: 9167-1979 IS: 3521-1983
: : :
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
1.0
ANNEXURE-B Format 1.0 HEALTHY, SAFETY & ENVIRONMENT (HSE) PLAN
Project :_______________________________ Contractor:_______________________________ Date :___________________________________ Owner :___________________________________ (To be prepared & submitted by each Construction Agency)
Activity Description Procedure/ W.I./ Guidelines Code of Conformance Performing Function Performance Checker Approver Audit Function Customer Review/ Audit Requirements
PREPARED BY
CHECKED
APPROVED BY
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
2.0 MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (1/6)
Project: _________________________ Date: _________________________ Inspection By: ___________________
Contractor: _______________________ Owner: ________________________
Note: write NC (Not Concern) wherever any of the items are not applicable Item HOUSEKEEPING Waste containers provided and used Sanitary facilities adequate and Clean Passageways and Walkways Clear General neatness of working areas Proper Material Storage Wooden Boards properly stacked & nails removed Cords, leads out of walk and traffic ways Scraps removed from the work site Other PERSONNEL PROTECTIVE EQUIPMENT Goggies: shields Face protection Hearing protection Safety Shoes provided Hand protection Respiratory Masks etc. Safety Belts Safety Helmets Other EXCAVATIONS/ OPENINGS Excavation permit Excavated earth kept away from edge Dewatering pump kept away from edge Safe access into excavated area Openings properly covered or barricaded Excavations shored Excavations barricaded Overnight lighting provided Other Yes No Remark Action
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (2/6)
Item WELDING CUTTING Valid not work permit Flashback arrester provided for cylinders Power cable not crossing the welding cable Adequate earthing provided No combustible materials kept near welding & cutting works Gas cylinder chained upright & kept in trolleys Cables and hoses not obstructing Screens or shields used Flammable materials protected Fire extinguisher (s) accessible Other SCAFFOLDING Fully decked platform Guard and intermediate rails in place Toe boards in place & tied properly Adequate shoring Adequate access Other LADDERS Extension side rails I m above Top of landing Properly secured at top & bottom Angle 70 from horizontal Other
Yes
No
Remark
Action
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (3/6)
ITEM
HOISTS, CRANES AND DERRICKS Condition of cables and sheaves OK Condition of slings, chains, hooks and eyes OK Inspection and maintenance logs maintained Outinggers used
YES
NO
REMARK
ACTION
Singh/barricades provided Signals observed and understood Qulified opretors Other MACHINERY, TOOLS AND EQUIPMENT Proper instruction Saftey devices Proper cords Inspections and maintenance Other VEHICLE AND TRAFFIC Rules and regulations observed Inspection and mantinance Licensed drivers Others
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (4/6) Item TEMPORARY FACILITIES Emergency instruction posted Fire extinguishers provided Fire-aid equipment Secured against storm damage General nemeses In accordance with electrical requirements Other FIRE PREVENTION Personnel instructed Fire extinguishers checked No smoking in prohibited areas. Hydrants clear Other ELECTRICAL Proper wiring & earthing ELCBs provided Ground fault circuit interrupters Protection against damage Prevention of tripping hazards Proper electrical cable joints Light poles secured Clear way to power distribution board Proper rating of fuses Yes No Remark Action
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (5/6) Item HANDLING AND STORAGE OF MATERIALS Properly stored or stacked Passageways clear Other FLAMMABLE GASES AND LIQUIDS Containers clearly identified Proper storage Fire extingui HSErs nearby Other WORKING AT HEIGHT Erection plan Safety nets Safety belts tied properly Illumination No loose material at height NO body under working area All openings covered Other ENVIRONMENT Chemical and other Effluents properly disposed Cleaning liquid of pipes disposed off properly Seawater used for hydrotesting disposed off as per agreed proceeding Lubricant Waste/Engine oils properly disposed Waste from Canteen office, sanitation etc. disposed properly Disposal of surplus earth, stripping materials, Oily rags and combustible materials done properly Green belt protection Yes No Remark Action
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
MONTHLY CHECKLIST CUM COMPLIANCE REPORT REGARDING HSE (Contd. 6/6) Item HEALTH CHECKS Hygienic conditions at labour camps Availability of First Aid facilities Proper sanitation at site, officer and labour camps Arrangements of medical facility Measures for dealing with illness Availability of potable drinking waters for workmen & staff. Provision of cretches for children. ERECTION Slings/ Dshakle checked Signal Man Tag line for guiding the load Protecting the slings from sharp edges No loose materials at height Ladder & platform welding inspected No one under the suspended load Stay rope SWL Yes No Remark Action
___________________ Signature of Resident Engineer with Seal
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
ANNEXURE-B Format-3 3.0 ACCIDENT REPORT (To be submitted by Contractor after every accident within 2 hours of accident) Report No:___________________ Date: _______________________ Name of Site:-_______________________ CONTRACTOR______________________
NAME OF THE INJURED.. FATHERS NAME.. SUB-CONTRACTOR M/S.. DATE & TIME OF ACCIDENT. LOCATION BRIEF DESCRIPTION OF ACCIDENT
CAUSE OF ACCIDENT
NATURE OF INJURY/DAMAGE
MEDICAL AID PROVIDED/ACTIONS TAKEN
INTIMATION TO LOCAL AUTHORITIES
DATE:
SIGNATURE OF CONTRACTOR WITH SEAL
To : : OWNER.. RCM/SITE-IN-CHARGE
1 COPY 1 COPY
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
ANNEXURE-B Format-4 4.0 SUPPLEMENTARY ACCIDENT & INVESTIGATION REPORT Project:_____________________ Supplementary to Report No: _________ (Copy enclosed)
Site:________________________ Date:_______________________ Contractor:______________________ NAME OF THE INJURED .
FATHERS NAME...
SUB-CONTRACTOR M/S...
DATE & TIME OF ACCIDENT
LOCATION
BRIEF DESCRIPTION & CAUSE OF A ACCIDENT
NATURAL OF INJURY/DAMAGE
COMMENTS FROM MEDICAL PRACTITIONER WHO ATTENDED THE VICTIM/INJURED SUGGESTED IMPROVEMENT IN THE WORKING CONDITION IF ANY
LOSS OF MANHOURS AND IMPACT ON SITE WORKS
ANY OTHER COMMENT BY SAFTEY OFFICER.
Date:
SIGNATURE OF CONTRACTOR WITH SEAL : : OWNER RCM/SITE-IN-CHARGE 1 COPY 1 COPY
To
FORM NO: 02-0000-0021F2 REV1
All rights reserved
4405E- 602
5.0 MONTHLY Health, Safety & Environment (HSE) REPORT (To be submitted by each Contractor) Actual work start Date:________________ of:__________________ Name of the Contractor:________________ Name of Work:_______________________ officer:_______________ For the Month
Status as on:_______________________ Name of Safety
Item Total strength (Staff Workmen) Number of HSE meeting organized at site Number of HSE awareness programmes conducted at site Whether workmen compensation policy taken Whether workmen compensation policy valid Whether workmen registered under ESI Act Number of Fatal Accident Number of Loss Time Accident (Other than Fatal) Other accident (Non Loss Time) Total No. of Accident Total man-hours worked Man-hour loss due to fire and accident Compensation cases raised with Insurance Compensation cases resolved and paid to workmen Remark
Date: __/__/__
This Month
Cumulative
Safety Officer/RCM (Signature and name)
To:
OWNER.. RCM/SITE-IN-CHARGE
1 COPY 1 COPY
FORM NO: 02-0000-0021F2 REV1
All rights reserved
~~' '47--\ .'9!: ,of ~~-
I Feb. r~..' 79 1'_' --.

P.D.!_L.
BARODA.
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-~~~.
Selection and Application
S_T~~_~ARDoj Protective Coating
ES : 2001
SHEET 1 OF 19
:ri((C7
1.0
SCOPE
This standard lays down tbe r~quir~m~nts for selection and application
protective
iD fertilizer
t
r
1.1
of
paint
aDd otber
etc.
(~" " ;
coatiol
piantl.
of exposed metal surfaces
of
equipmeDt.
machinery,
pipiDI.
structure
1.2
This standard allo includes recommendedcolour code for equipmeDt, machinery aDd piplDI.
1.0
REFER.ENCESTNDARDS :
IS: IS: "IS: -. 1477 Part I Code of practice for paiDtiDg of Ferrous Metal io Buildiog : Pretreatment. 1477 Part 2 Code of practice for finishing of Ferrous Metal in Buildings: Paintinl. 2379 IS: S Colour code for pipe linCl. Colours for Ready Mixed Paints. ( -! ",
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3.0
GENER.AL:
3.1
Paints and otber material uled for paintinl sball conform to relevant IDdian Standards.Wbere no IDdiaD Standardsexilt material shall conform to otber recopi5ed Standard specifications.
shall be 'Ule4.
wbich ODly paintl bave been duly approved by purchaler as TCJard~ype. make aDd quality
:
.
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3.2
3.3
The following surfaces shaD not be painted: a) Piping ..eS5ell aDd other equipments to be inlu1.ted
b) Alu~ioium. plastic pipe. ~al"anised asbestos iron, cement stainless unless steel. .specified brasl
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received with shop coats of primers, the inlulatioD caD be applied over it ).
copper and other otberwise
for hot service ;'in case these are

nonferrous material,
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Name plates. Valve steml, control YalYe/safety valve sprinlS. sbartl or other sliding or wearinl surfaces
"'.
All shop fabricat~d structural steel items and equipment wbicb require painting sball be given a priminl coat of R.ed Oxide Znic Chrcmate primer ( to IS : 2074). unless specified otherwise in tbe shop After erection these surfaces shall be tborou,b.ly cleaned to remove dirt. grease 1.fid loose-scale aDd al1 blemishes made good before applying -the fiDiShcd c~ts SELECTION OF fAINTS
"."
---P-
4.0 4.1
&;. PROTECTION COATINGS:
."
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;
Selection of ~ints for various surfaces and service conditions, number of coats to b~ spplied and preferred colour shall be as per Table-l Howe..er; in view _of. coat1u-umg deyeiopmrDts i!J paints ~te~.bnololi, otber types may be used provid~d tbei; satisfactory field p.rformcnce
has been proged.

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ENGINEERING51ANDARD__Selection and Application of Protective Coating
ES : 2001
SHEET 2 OF 19
I ': I -.. "BARODA.
4.2 Primers and finish ensure com

p atibility.
coats
for aDY particular
system shall be from the same maDufacturer to
.
. i
4.3 Limiting
temperature
meDtioDcd
iD Table-l
are operatiDI
temperature
of equipmeDt,
pIpIng
aDd
structures.
:
I
5.0 5.1.0
~ 5.1.1
ApplicatioD
of PaiDt : I;.
of protective paiDting scheme can be achieved only wheD tbe meta]
Surface PreparatioD.
The maximum durability
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surface bas beeD correctly prepared. Tbe duration of protection is decr~aled often sbarply. ii painting is done over mill scale, rust and otber contaminants such as gr~.se and oil. Blast. cleaning though costlier is the most leliable procedure for obtainiDg surface fre~, from mill 5calc and rust. Their superiority over hand cleaning, wbicb always leaves mucb rust on the surface and often some broken mill scale al well as shown by tbe following tYPIcal results of test In an indus[rial environment.
a.ESUL TS OF TESTS ON PAINTED
STEELS
! !
AVERAGE Surface preaparation :. -Blast Cleaalng Wire Brusting
DURATION
OF PROTECTION 4 coat paint system years -10.3 2.3 -
2 C08[ paint system years 6.3 1.2 dirt, oil, trease,
~\
5.1.2
The surfaces sball be cleaned to rem;ve all
rust, scale and otber contami-
--
Rants. This shall be accomplished by blast cleaniDg. chipping ~crapping, wire brusbiDg ftame cleaning etc. The proc~dure to be adopted for cl~.nilJ& shall dep~nd upon tbe coDdition or steel surface and sball be decided in consultation witb the F C.I. How('v~r, blast cleaniDI ia a must for synthetic costly paints like cbolorinated rubber, ~pc:xy bascd paint etc. The acc~ptaDce standard of sand blasted surface shall not be inferior to Sa 2! to Swedish standard SIS 05 5900 Oil and grease shall be removed by use of suitable solvents, subsequently tbe surface should be washed down with clean fresh walcr- and allowed to dry. Flame cleaninf
shall only be used after obtainig prior approval of PDILIt shall be cnsur~d tbat sand blastca
.i
t
.
I
surface is not contaminated with oil and grease. Water shall also not be allowrd contact with the sand blasted surface.
to come in
.-
5.1.3 When paint is to be applied on damaged painted surfaces- a!lloose a!1_d flaking paint work. should removed to a firm fcatbered edgeT--Rusted spots should be cleaned by one of the methods -- specified in tbe clause 5.1.2 in case the previous paint work is no(- compatible te the specified once [h= entire coatinl should be removed.
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BARO
(;
ENGINEERINGSTANDARD
Selection and Application of Protective Coating
ES 2001
SHEET ", 3 OF 19
A.
5.1.4 Where high temper8tures are involved (~
120C) surface preparation
is exlremly
importaDt
I .
:
and blast cleaninl IS minimum recommendation.
5.1.5 The procedure and equipmeDtfor IDrface preparation Iball be in accordancewith IS: 1477part I.
5.1.6 Preparation for surfaces for paintiDI other than steel. 5.1,6.1 PreparatIon of masonary. concrete and plaster surfaces. I. ProjectinK finl. nibs. mortar spatter etc shall be removcd by the affected areas sanded or rubbed smooth. Mortar joints sball be raked clean scrapping, rubbing etc : and
C~
2.
3. 4.
Crack-s, voids etc. shall be filled with an approved spackling compound and sanded smooth Surface ready lor final paiDt finish shall be through)} been cured for at least 7 days perior to painting. dried free from moisture aud have
5.1.6.2 Preperation of wood surfaces
1.
2. 3.
Surfaces shall landed smooth.

Primer or wood sealer shall be applied. Holes, splits scntches etc ; shall be puttied or filled with suitable compound primer bal b~ea applied. and affacted again sanded Imootb. afler the
) C)
4. 5.2
Untreated woody if any shall have the sapy knob
and gummy spotl
scaled with shellac
Painting procedure
5.2.1 A freshly prepared, bare steel surface is particularly liable to rult The iDterval betweeD surface preparatioD aDd paiDtin& .hall therefore. be al short as practicable I especially if there is danKer of condeasatioD) and in no caes IoniC! ~an 4 hours. Unless a particular method
of applicatio-n
IS specified
primers
and--finisb
coati
may be applied
by bru&binl.
con~eDtion.I
air or airless spraying or roller coatin& Re&ardless of the method selected. the equipment or tools for applicatioa must be cleaD and in lood workable condition. Tbe application procedure shall be in accordance with the rccommendation of the paint manufacturer aDd IS: 14i7 part 2. 5.2.2 Where 2 coat "f finish paiDt ~~c iDd~ated--tbey shall -be applied ensure that two coata ire applied. 5.2.3 Paiot stlall not be applied iD rain. soow, fOK or mist or aa to cause condeDsatioD on metal surface. in two different abades to
wbeD tbe relative
humidity
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P. D. r:L.:
ENGINEERING STANDARD
. 'ES
.
2001
,~
BARODA.
of Protective Coating
SHe ~ ET 4 OF 19
5.2.4
PaiDt snail Dot be applied wben tbe surrouDdiDI air temperature i. below 2C. Dor wben temperature is expected to drop to }.C before the paint has dried. All surfaces shall be perfectly dry before and while being painted.
5.2.5
5.2.6 All iD&redieDts in any contaiDer of paint sball be tho!'OUlbly mixed before use and shall be mecbaDlcally alltated continuously during applic8rion to tetp tbe paiDt in suspeD.ioD. Dry pi,meDts which are separately packed shall be uDiformly bleDded into paintS.
5.2.7
Thinner shall Dot be added to the primer or paint unless required iDstructlons and tben only of the type anc quantity recommended. Storage:
by
tbc
manufacturer's
60 6.1
All paiDu aDd paintin& material shall be stored oDly in such rooms asli,Ded for the purpose. All necessary precaDtioD sball be taken to prevent fire. The storage buildia, shall preferably be separate from adjaceDt buildinls. A sign-board bcarin, the words "PAINT STORAGEDNO NAKED LIGHT" sball be clearly displayed outside. The building sban be properly ventilated and sball be adequately protected with fire fightIng ~quipm.nt. Colour Code for piping: For identiication or pipe lines, the colour code as per Table-2 shall be used code i. leoerally in accordance with IS :2379. The colour
7.0 7.1
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7.2 :
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The ground colour sball be applied to entire length of pipe, except where aluminlnm paint i. sprcified. Colour band sball be applied at interavals of about 10m and at junctions, valves walls etc The relative proportional widtb of the first colour band and subsequent bands shall be 4:1. However, tbe minimum width of tbe narrowest colour band shall be 25 mm. The around colour sball extend s~fficieDtly on both sides of the colour band to avoid confusion. In case the paint in tbe colour as per Table 11 is not available, Syntbetic Enamel of the colour specitied in Table II shall be applied over tbe speeified ground coat to a leng'~ of 1 meter at aD interval of 10 metres.
7.3
Furtber ideDtification of conteDts ~o_SDppl~m~n~ the colour code shall be d:JDe iD the. case of major piPe lines by the use of lettering. desilDating name or standard abbrevatioD f~r tbe 8uid iD clearly visible locations. Arrows indicating direction of ft;>w sball be p:iintcd in contrasting colour near valves, juDctioDs walls etc. aDd at suitable iDtervals alona tbe pipe length.
---- - --
7.4
7.5 . . -; - -.,,1 _.! ., \ ~ ~." ~. : 1
Pipe lines carrying toxic aDd bazardous ftuids sball be painted with bazard :Darting digonal stripes of golden yellow and black at suitable iDtervals.
with equal
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-.a.-- Selection and Application
P.D.I.L.!
BARODA
ES:
2001
SHEETS OF I
. -
8.0
Identifi-;ation
of vessels etc. ODeach vessel after paintinl.
Name aDd equipmeot Dumber shall be stencilied in black or -bite 9.0 IDspectioo aud Teltio&.
Tbc work shall be subject to inspection by POlL Inlpector dariol ftrioUi stalra o-*' paiotio&The coDtractor shall offer the works for inspection and approvaJ durinl evry stage before proceediog to [be out Itage.
"CI-
9.1
The following inspection shall br performrd duriog various sl8Jes of paiotiol Stagles Prior to paiotiDg InspectioD Iteml. (I) Material
work
(2) Dilution (3) Surface preparatioo. During painting (I) (2) Number of coatings. DryiDI time.
After completion of painting.
(1) PaiDt film thickness. (2) Fioisb colour. (2) Appearance. (4) Ideu(tfication. marks.
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Any defect no.tic~ during thr variou! stages of.i nspection sh~1I be made good b.y the c.ootrac(or to the latlsfacttOB of PDIL before proceedIng further Irrespective of tbe Inspection. repair aDd approval at intermediate stages of work.. contraCtor sball be responsible for makiDg good aDJ defect fOBad during final inspection and guarutee period. 9.2 All paioriog material shall be accompaoied by manufacturer trst certificatrs. Jo case such crrtificates arc Dot available. PDIL may direct the contractor to bavr the materials tested 10 accordaoce with rclCYent I. S. specificati~n at POll/outside laboratori~s aDd all costs there of shall be born by~c coo!r~ct~r. PDIL at its discretion IDaY call.fcr additional trsts for materials accompained by maDufacturerl tests certificates. Co.tractor shall arrange to have such tests performed but costs there of shall be borue by the POlL. 9.3 9.4 9.5 Dilutioo of each paiat shall be checked to meet the requiremcats specified by paint manufacturers
.
-
-'
$:~rface -preparatioD stia-nbec visually checked to meet the rC'quir~ment specified in clause S.lO Number of coating shall be in accordance with Table-I.
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BARODA
ENGINEERING Sf ANDARD
ES:
2001
SHEET t; OF 19
9.6
Dryiol duration shall be in accordancewith recommendatioDl of paint manufacturer. Drynes5 of previous paInt shall be eosured before subsequent coatinlFinal inspection sball ioclude measurementof paint film thickness, check of finilb and -ortmanlhip. The thickness should be measuredat Je:1stat 20 points and Ihall be witbin :t: 10~~ of the specified thIck-Deli. Tbis would exclude dry DIm thickncs of residual shop primtcr if applied. Tbe contractor sball provide thickness mealurlnl inltrumentl ( Elk.meter ) accesa laddera. lilbting and any other item oeces.aryat hil cost. Tint of fioisb colour sball be ch~ckedvisully. It shall also be cbecked that the coated surface are free from any deterimental film irregularities sucbas lifting, pee liDI. crack and nonadberance.
9.7
9.8
i \,-
\9.'
9.10
'\
Colour code and identification marks of pipliDes shall be al per clause 7.0
At tbe discretion of PDIL, the paint manufacture may also aslociated with tbe inspection of the paint work to eDsure satisfactory application in conformity witb tbe procedure laid dow. by them. Any defect pointed out by tbe paInt manufacturer sball be made load.
10.0 Guarantee: 10.1 The contractor sball guaraDtee that the cbemical and pbysical properties of the material are in accordance with tbe specifications laid down by POlL. UI~
10.2 The contractor shall also ruarantee tbe painting works agaiost defects due to bad workmanship I use of inferior materials for period of onc ycar from thc date of the completion of the work.
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1- '- - - E~!!~~ING STAN~ARD---=I Selection and ~pplicatioD of Protective Coating I

TABLE-I
ES : 200-:'
SHEET 7 OF 19
.
SI. No. DelcriptioD Temperalure
.-
Primer
FiDilb PaiDt.
Prefened Coloar for equipmeDts.
I.
Vessell. Towers. ExcbaDlers and pipiDI (Bare). UplO 130C Epoxy based Red
Oxide Zinc Chro-
\w~
1.1a In extremely corrosive

eDviroomeal
C
Kith build
epoxy baled
Grey
\...
splash &; spillale of
like
mates/Zinc Phol-
Paiat(2coats) 200 microns.
acids. urea, etc.
pbate rimer (I coat) 2.5 micrODl UplO 65C
.
Dark Grey
1.lb
10 corrOlive eovironmoot like Exposure to salt du~ acid, acid fumes, etc.
Higb Build ChloriChlorinated oaled Zinc PhosRubber base phate primer (1 coat)paiot(2coatl) 50 Microns. 80 microDI.
UplO 120C
Eposy baaed Red Oxide Zinc Chromale/ZiDcpholpbate primer (1 coat) 25 microDI.
Epoxy based paint (2 coat) 80 microns.
Dark Grey
I
~/
Above 120C
Silicon base paiDt (2 coats) 40 microns 2 coats Red Oxide Zinc Cbromate pnmer witb modificd pbeaolic Alkyd base (15:2074) 50 microDS. 2 coati or Red oxide Zoic chrome primer wIth modified pbenolic Alkyd base ( to .15:2074 ) 50 mieroDs.
-
AlumiDium
1.2
- --
In ordinary environment and outdoor locatioas exposed to atmolpbere
Upto 120C
2 coats Syntbetic Enamel to 1S:2932 50 Micr~D_I.
Dark Grey -
-- - --
"
1.3
Fuel Oil. Tanks, _Lube oil_ranks
Upto 120C
2 coats of SYDtbetic eaame) ( ta IS -: 2932 )
Lilht Brown (41.0)
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ENGINEERINGSTANDAID
Selection and Application of Protective CoatiDl
.
. . ES 2001
;.,
.
BAI.ODA
SHEETI OF 19
! r
~1,
1.)cscrip&IOD
TABLE-I T cmpcratur8 Pr.er
..
FiB-
Pnf'8r-
No.
-
PaiDL
CeIoer fer
eq8iP888i.
..
~ ..
~~.
1.4
1. erdiaary _liDe c8viroomcat.
Hip aMildZiac PbOlpa18pr18er

SYD&h~
'f~
2
~
:'1 1
).
B:.h hi..
DaI'k
Yicaceou
I..
~
an,
Iro:8
0Kw.
Lead pl'l8er ,
\'
-,
( IS 102 performaD"
pem. ( tW8
C8t1)
.icroaa
,:~
';,
210
~ ~~
-',
:I
:
~] ..
2.0 . .. S...
2.1 Ia ~
$apport ...~..rn etc.
~~..
~r.m
-Not applicable for pipa (See ~2)
Hip 8."WQloriaatcd QIori.ZiDC~ pMtc ~ (1 ~)
~
~
~
2.2
:;..
~~I :w:;~.
Ia
,-
--~
., '-'\'-
.-.
f--
lib _.at d8t,
SO .i~
. 8icr-.
:~
~~I
~~~-pai8t (t-.
.. ';;8j-~~ ~
7 ..w-.
to
IS : 2074 (tw8 cab)
cbro8te ,n.cr
Red 0sid8 Zi-
332 (~
D:
~ ~.."
". -..
. ~ -icr-.
~18)
588icr-
0..,(G2J
2.3
I. s.I*
ea.u-~
Hip Zi8C pboapMte pri88r

(o_~)
2. ~t8
W. ~ Mj~ a.. -
~. 0..,
'" ~~ ...
...
~~
.
2.4 -Stair" T..c8d, - Platt...
---
~Pi"-- tic LCia
S,.~
10
.-cc.
--
.--
IS: 102 ODe ~
,...,
~ip
of blackbit...
T~ ~ ~t nil4 - MiId_~
Gratiap-.
thiDDer SOmicro.- -
thieDed .ill.so ~
bit88ea ~iDt .icr_s.
..~---
Black
- .;~'-~~...'
~
,
-;"
PD f L
BARODA
-
Selectionand Application of Protective Coating.
.--
ES : 2001 SHEET' OF l'
'-
I
I
51. No.
DeacripllOG
Temperalure
Pn8er
Fiailb Paiat.
Prcfcned Co for cqaipe8eaL
,
.
3.0 Bud Rails

C- '
'--
Oaecoator kilb build

black bit88C&..iat
thiaaed with .50-;' tbiDaer SO aicroaa.
OM coatof kip.ct
baiW black bib...
paiat 100 micro...
j
I
4.0
Stor..e Taab
.
j
A,..cr-..
4.1 Ia _~Iy ~osi.c Upc. Hip BDild Ot.loriDalcd
~.
I,
Cbloriaat8d
~k
_..~~
~~,. . ..
8CW '-n.
lit:c
etc.
6.5-C
Ziac PboipMle pri
(oDe .coat) ,.
micr8U.
pai81 (I-. ~)
80 8iCr8a.
&8ki'
-.
0-,
UptO
EpeQ baled I.ed
EpaJ bMe4
12rC
~
-\
o.icIe Ziac Qromat8,Ziac
,.mt C2 coaD)
10 .icr-.
0..,
~
(1 C8t)
~-
. pba~ pri-4.2 la"'~ 89i-
2S micro8&.
.
- -- -
Re4 Oxide Ziac
~~
~. - -~.
r~~~ aM "'door: lecaa-.
-~
. .-. r~"
---
C~romatc .-.i-er IS : 2074 (2 coats)
50 8icte-
pai8t Ie IS : 2339 (2 C8U)
50io-'-~
- - - -
- ---
- --~ ~
--
- :-. --:-:- . - . .-
4.3 .. ~8UJ ... ,

- -.
H"ap Build ZiDC Pbospbtc Priaer

(1 coat)SO aicrou
or SYDthctic Lad Pri.er to Red IS :-101-
Hip Yi~--hiW
1roao.D4e
Paiat (2 - -- coata} .icroas
_pcrformaocc. -~ -
-,
--- -- - -.- --
- -
-- --
_.
-.- -.
.
'" k;{.:,(%~~~r:;':
"
.
~
:"i
"-:1.,
:'
p, D. I. L.
BAROOA. ~
ENGINEERINGST A"DARD
ES S-eJectionand App'ication of Protective Coating
:
2001
of 19
SHEET 10
.,
J
'
51.
No.
Descraptio.
Temperarure
Primer
.paiat Fiaiah
2 coata of AJU8iai..
a.efenedfor Cotov
,
CCI'~ts 5.0 F..uce .. Flue 0. ducta. Upto I~C 2 coats Red Oxide Zinc Chromate Alu.iai..
c ,-. ud SI8Cb~
l~ to 2OOOC
primer to IS 2074 SO microDi.
.-i8t (IS 233f) ~ 8icr-.
2 c.ca of
Heat Railtiaa AlaaiD.ium Paisl 40 .icro8l.
AJ..iai.
...
Y.miHry (r;:-:Wi:~-=.
8IC.
UplO
S4OOC
,~
-..
S~. 40 .icrou
of Beat
AJ88iai-
Pm,
!
: r
'-0
w-.en. ~"r..
~,
i
I
Ua - au ,
Upto
Epoxy t.Md
Red
Rip
88iId
On,
~..i.. .--i.-_I lib
1WC
--. --,
& ~~
01
UplO
6S'"C
Oxide Ziac ~ mate/Ziac~OI~t.
primer (I coat)
2S microaa.
BpaaJbalM ,... (2 c-.Ia)
- 8ier-.
8Ic.
6.1. .. ceuoaiwe 6..0.~ lib ~--r ~. .. ~ d81. acW.
.Hith
Build ChJoriaat-
QJoriaat8d
Sa C~
ZiDC PbOlpbat. PrilDer (1 coat)
R~ -pai8t (2 ~Ia)
--
'-
8tc. Upto
l"-C
SO laic r0as Epoxy based Red

Oxjde Ziac ~te/
. iO8&: ~ EpoZJ -hi.

-
Sa ~
.-
Ziac pri8C Pbo.uta r- 258icr--.
.
-
2 ~
~
-.
A...
1~C .
Sil~
pai8I (2 C88I8) "8icro-. Red Oxide ZiDC
Chroma&8-pri.e~ IS_: 2074 (two coats)
=
~i88
.. OfoCiDary
Upto
~~~~_E--,2t)2(2 coats) -
G
--
aYiroemea&-
12Q8C-- . -- -
50 microDL
. ~ - - -
SO.icro...
-
~;;
...
'"
~:i:,.:
-'.. , "'i~
"'!Z~
'.."-::~;~~."-::
. . ,'. .'::...
P D
ENGINEERING Sf AMDARD_Selection and Application of Protective Coating
ES: 2001
SHEET11 OF 19
BARODA
-.
.
51. No.
~3
Dacriprioe
Temperature
UPIO 1200C
Pri.er
Epoay bued Zinc ChromatefZiac Phoaphateprimer (one eoat) 2S microu
FiaPajat.
Epoxy Baaed
PrcferRd Colo... for

eqaipe8CDL
ID saliDe eaYi..ODlDent
Sa GRCa
pai8t (two coati) 10 Micro-.
(
,
7.0 Cra.a. Mo..,

",
L,
7.1
parts
or ~iaery Hi,b Build Q1oriaat~ Ziae ~OIpbatc Pri..

(1 coat) SO
(like rotary drama)
b hitbJ'1~.Aiy. eaYir88Cat like ~.

fa miary e8Yi.~
Ch10ri818d Rubbcr IBM

paiDt (two ~U) 80 mia-.
upoeue to aIt, duat ' 'er acid er acid fumn.
micrODl.-
.
1.2
Red Oxide Ziac Chromate Pri8cr to IS : 2074 (two cab). Hith Baild Ziac ~OIpUtt prilMt (OD8 coat) .so micro.. or SJ8tbetie Red Lea4
Primer to IS 102
SJDlbetic E8-~ 15:2932 (twe CO&I8) SOmicr-.
1.3
1. SeJiM 818O8pHrc
Hip B8iW
Mj~~ 1..08 Oxide pam. (twe coata) ~
mieroa.
..,.,..
"'"""-'
.
1.8 Ek i;i"~~. ~ U-~' 8Iectrie
performance..
,.~-.
- .
~~
~ ~_..
Bke
~~~ 1.1 fa ~
C8,.j~~
Upoa8n
-' EpoaJbuc Ziac

Chromate/Ziac
--
~- -,peial (2
.icrO8L
- --Sea
Grc..-
.
'"
or acid
Epoxy MM
aIt.
-
all
-.
-
Phos~ate primer
- -Chrome primer ~ IS 2074 (two CO.b) .so:micro-.
coaU) .
Sio~etic
(2 ~ta) SO microDi
--
ctc.
(1 CM.t) 25 .iCrO8I.
--
--. ,
1.2
.. .~di-.ry
-.ir...""',
. .-- - -
- -
'-' R.Cd Oxide Zi-c
--
Dark
Grey
."
eDa8el : IS : 2932
- - --,-
.
" ~ ." ,". '. ,,!i~~,,;fj~"
. -
--
, , I kt"
- .,
"
,.
P.D.I.L.
_c
--
ENGINEERING ST AIDARD --
ES: 2001
HEET 120F 19
BARODA
.Selection and A.pplication of Protective Coatina
51.
DclCriptioa
Temperature
Primer
.Fiaiab
Paiat.
. . ':
,j
He.
Pre(ared CoIoar for equipmcata.
'
1.3
I. Saliae
al8O8pbcrc
Epoxybale Ziac
Qromate/ZiDc ~hat. primer (1 ~t) 2S .icroal.
Coal Tar Enamel as per ES 6009
Epozy baaed
paiat (2 C(au) 10 8ic
SGrca
";
I
P: .
~;'~
[~
'.~ , .:; '.0
1
"'-
.ari~
Pipial
.y f:~~
-.
M.O GasHokien. Tanka

A iuide of lifu
Red OxideZiac
- h : 2074 (2 coals) SO
2 coati Cbloriutcd
Rubber paiat
Cbro..tc
primer
~t ~-~ ~~'
&ad crOWL
10 _iCIO8L
--
aaou.
08!y wkea ..rfaa iI 8M blastAJlu.tiyeiy :
I ~of H. ..iW -.ct Pri_2S
2 ~Rip 8wiW 88act fia8M
_r~..
10.1 A.coaIiaa ia co-.. witb water.
",---
.a...
Bilk
1 ~
I ~
~
black
Baild bact
..iW
.~-
. Pri.cr2.S
~ou.
kiaaeo .
2~
..
10.2 ~~.
of lifta.
Two c-.tI Red
~,..8icr-.. 11.8 "--~ -11.1 ~ _rfaca. eqai.-cal --
Oxide Ziac
~IS : 2339
,,8ic1a8.
,n.., ~
- -
- - - -- -
-- ~
--
.,.
..
piPi8I 8tc.
11.2. YaaiM Mae A Pti8I8 .
11.2.1. Ma'"
" "..-
aJ--i88 ,..
to IS : DB
.
.
ordlD8l'J'.
~A;
. ..-
-- -
Bit8__...nc - Coal Tar 8PGZJ pafDt to
BcaYYaty
- "-
11.2:2 Where spill... aad sp1aah hid. ~( corr~jy. . - -.
-', -- - --- -
-"
-- -
Coal Tar Epoxy

paiDt thiaDcd to live 60 mic.
.-
P8
150 -icroa,
.
. , '.
"".:-i-._",-,,: -'~""
ij
'
"
,
J
"*-'~ ~ '.~;~""-~""::;p~'~'-"'
..-
~~"
-"--,""",,~,,:=,~~~-~,
,,-
or.'.
,.:"'::;;c :..
'
--"..",~tt;~--f".~
"'p
.,.
'
-~
.'.~
'
;
--'
:
:~
'. P.D.I.f,..
BARODA
~IGIIEERIIG~ ~!!~_DAR~
Selection and Application of Protective Coatinl
.
ES : 2001
t ;
, .'
'"
HEET 120F 19
51. No.
:I:- .
DcacriptioD
TcmperatDre
Primer
Fiailb . Paint.
Epoxy baled
paI.1 (2 cla..) 10 aic
Prefcrr8dColo. r... eqsil8C8"

Sa
Grea
~
.
.
J
...
8.3
lD Saline
atmolpbcrc
EpoZ'f bale ZiDC

Chromate/ZiDC PbO8pbate primer (1. ~t) 25
" t. ~ '" '!f

.
,
~.
t.O
8aried PipiDI
8acr--. Coal Tar Ea8cl
f-;' "
,
,.
J
.. r~
t:
. .
::-',
-. .
ES 6OOt
2 coati Cbloriuted Rubber paiD-I
,.:.
10.0 Gas Holden. T8DU .':! a. iDlici. of lifu aDd croWL
Red Oxide Ziac CbrO8ate primer

(2 ~U)
. , .;
w
f.~: '
. . ~
~~
4
- II : 2074 It microu. o.Iy -- '.rface

IDiCf08I.
.so
...
is IBM
blasted
,oc . ,r,," ~
AJtenatiftJ,
1 CMt of H-
2 ~.. Rip
..iW Black
Pn..25
8K1O8I.
1 _t
B8iW 8act
r.. 8icI8L
1 C8t
10,.1 Ar-
~i8I
i8 ~
B"IIh
~
~
110
wig _cr.
-~
B8iW*t
Pri8er 25
'-ill
~
Red 2 ~
'-
10.2 ~~
of fIL
l8icrou..a-..
T~ CMU
A~
,ai8& Ie IS : 2339
.'
OM. Zinc
ca.-tc
11.0 "-~~..r.ca.. 11.1 ~-=~.. pn.. ai
~
.
01
~;a:c
- -~
.~-
- -
--
--
-aJ88ia~-;i:-.te IS : 2339
BaY)' d8ty
0.. -'
--
.
-
11.2. ..~
~
-. . - --
- .- --
11.2.1 ~-~ pila11.1.2

- .pI8ib
ft-IPi~"
b88e a ~i8J'7. -- -- -
8ita8i808 - -
--tic
-of ~r_~.
~ ---
Cbal TuEpozy pew. tbiDed
Coal Tar Epozy,..at ~
bid. . -
to
lift 60 mic.
-
Ii.. 150.iC1'on~
--
\. --
t.
..
~
;i
:~
..
...:.
-
-5-1"""
-~.,
" "
~:,~.
,-
P. 0, I. L. BAR-ODJ\..
ENGINEERINGSTANDARD
-
'
ES 2001
SHEET 13 OF 19
SeJection and Application of Protective Coatina

.
.
,
~ ,;
. ~
"'-/
'.
'
51. No.
Oescriptloa
Temperature
Primer
Fiailb hiDt.
Preferred Coloar for cqaipmeaL
11.0 Fiber liasl reiDforced

plastic liDe'S (wben comiDI ia coDtact With reacti08S fumes
(If Dot used with fibre 11811rei. forcemeDt) Flood coat
Bi_nol
raia
coatai8i81 fluoriDe.
paosplarie acid pia at).
of 0.5..
(approx)
~
~
..
,...
'
:4
~ "..
c'; ~
" ",
a
;
~ ~
.I ,
--~
NOTES:-1)
"-
Fire equip.eatl -0
a,.-rat8
_all be ~iated fire red (536)
2) N...ben ia ~rackeD an id~lifyi..
.a.bcn of colo~ - per IS : S

.' .
3, For ideati6eatieeof pipiftl. seetable-2"Coioar coGef pipiq-.
~ i"
- -..
-- . -
---
--
. -. - --. ,. . -. . - . . -:..:-.: - - - - -- --- ..--.

" "
- - - - . -
--
--
- -.
-~ .
i
. ..
~.
--~-cc
. -..;..
COo
-. "~cYi~
~':ii!!
0
P. D. 1.L.
BARODA.
--
EMGINEERIIG STANDARD
ES: 2001 SHEET14or l'
Selectionand ..(ppJicatiOD of Protective CoatiDg

TABLE
.
-~
51.
CoD teDts
Gro~
Colour
'Fir~ ColoDr
SecODGColov
J
;. ~
Mo.
Bud
BaDd
I
i
i
1. G88
i
~ .,
\
1.1 AIAaoeia (0.. or Liquid)

1.2 OAJIC. .1.3 HJdroaeD
Dark
'r8let
(796)
White SilDaJ 1.(537) Frcach Blue (166)
i
1
CaDaf7 Yellow (309) CaDary Yellow (309)
; ;
',
1.4 NitrOlCD
1..5 Nitrous G.. (Nitrous Oaide)
Caaary Y clio.. (309)

Cuary Yellow (3Ot)
Black
'French Blue (166)
-.
~k
~t Violet (769)
:
i
L'
~is
.ixt.n
Gu
Ca.aary Ycilor-(309)
Caaary Yellow (.109)
Sipai aM (537)
S'18&1 1.- (537)
'.
1.7- Ceb 0...
~ .I
..
1.1 a~-:;-;
GasI N. Gas
Caaary Yellow (309)

Caaary YcUow (309)
Sipail.ed (.537)
Lilbt any (631) Si,.ll.ed Si.-l1.1d (537) (97)
~t
Or.,
i
;
1:9 c..~ioaicIc
1.10 MctMM a:. Otkr BJdI'ocarbO8
~t w.it8 8rowa (410)
~ i
c...ry
c..ary
Yellow (309) YeDow (309)
j,
1.11 0. 2.
'"CC,,--- 2.1
M. Ga Guiicatioa
form Naptba or
Air
C-~e..ecI Air
Sky ~
_1
(101)
SiIMIl.8d
(.537)
\-
2.2 1Mtr
,
s. ~~.. 1.1 W
3.2 :'"i~ --
u;
Air
Sty 81-
(101)
.-:-
Water
Sea G.- (217)
Fr.a ..
(116)
.-
.. , ~
water
3.3 3.4 Driat:ial
(:0.._t8
.-
Sa Gr..
Sea G~ Sea G~ Sa GI'..
(217)
(217) (217) (217)
L__t Or-.
Lipt 8 Ftcaa
('57)
(410) (ll')
-=
Si8Dal Rcd (537)
.
.
_.
3.5 8oiiCl' Feed ~

-. 3..'-~--R1Yer
Whit.
Silyer Grey (628) if Bitulac .. AI jacket. -
--
----..atl'catecI
. - .
- --
SeaO~
-
(217)
4. -" I,.'
Stea8
3..5k8Jcml
BrilliaDt areca
,
,. l. fr,-,
-.
: :-:
--
'
.
.
c'Y
..-c
:;"",!:;",
,.
,.,;
,
;:
,
"
- ,
P D I L.
,
ENGINEERING 5TAMDARD
]
ES: 2001
SelectioD aDd~~PPlicatiOD of Protective CoatiDS
.
BAR.ODA
SHEET 1S OF 19
:
I I j
TABLE-2 (CoDtd.)
SA. Coatcnts Grouod Colour Fint CoioDr Band SecoDd Colour
t
.
I
'
i
No. Steam 3.~20 tl/C82 Su.u 11'81(628) if Bit8lac er AI jacket.
Bud FreDda 81..
,
..
r ,.'
-)\
21-40 ta/cm2.. 4Oklicm2..
Dark yiolet Sipal Red
5.
MiKellancoul
Baack ~t Brvwu (410) Lilht
Lilbt
S.l Dr-aiDqC U L88ricaliOS
~t
,
lrey (631)
~c"
Oil
5.3.. f8d
~
-"
Oil
"WD. (410)
BrowD (410)
S.4 Tr88IfOl'8C1'
-.,OiI
FreDcb Blac (116) Lipt OraDI. (5.57)

I,
,~
6..5 Mee~
Deep Bel:' (360)

r --~
-..,--s 7:1 MEA Soi8tio8 1.1 c...tic Soda IOIwt.. 7.3 A8aa0a88 Carbonate!
7 ~
--
'
Tura Cola (444) Tcna Cog (444) T.ra COla (444)
Frac~ BI.. (166) Caaary Yellow (309) Su.u Or., <621}
~,~
Cuboa . Ie
..
~\",-
SolotiOB.
1.4 ADUDO8i88
Nitrate lOIuti88.
Du-k '-lOiet (796)
Golda
Yellow (356)
1..5 1.6 .' 1.7
NaptAa V.u-uWu SoI8tioL Wak Acid (&NO,) 8,-0 2Qilj. Upro"" ~ ~ Yak - .-
Lipt ~WD (410) TG'ra COla (444) ~k V-lOlet (796)
Black Deep Ora8Ie (591) Lilhl 01:8.. (557)
1.8 Acid (~)

--
--
~k ~k
V-lOlet(796) Violet (796)
- -
wpt =
(410)
- Sal~
-piak (443)
13
Silver Grey (621)
I."
P~OL Acid CODc.
-do-
-do-
&cd oxide ( 446)
1.11Pbos.Acid Slarry
1.12 ~._AcicI, Vcat Gas. 7.13 H2 SO4.-Dila.. 7.14 -do-Coac--
. -. -
---, -
-' - -
. -
-do- _..:.:.-: .-do-
Liabt Sal~ ::. ,piOk-('4:4;2) ---=alack -
f;.aDarJ Yellow (309) .. - Dark Violet (796) -do-
BriUiaat GreeD (22.1) -do--
Liibt oranle (557 Sipal red (537) -"
~-
.I , : ..,,' -. ".
~,~
".
,,';
.-
",' ,
"..
"
,.~...
. .
,
.
P.D.I.L.~~NEE~ING_~!~!~~~~
",'-'
Selection and ApplicatiOD or Protective Coating
ES
: 2001
.
I
f:
BAaODA
HEET160F l'
TABLE-2 (Coetd.)
51. No.
~. r.}
CoutcDU
GrouDd Colour
Fint Colour hDd
SecoDdColour Bud
7.15 OIcum
Dart Violet (796)
Lilbt Ad_iraijt,
JradC (632).
Lipt
(442)
Salmon piak
:;~ . ,7.16 ~.c' ~ 7.17 .. Fluoailicic Acid. Poly acra8ai4a -doBlack
Smoke lTC' (692) Azure Bluc (104)
-do-do-
.
!
..
. .
I.
Coed.iu-Lilbtiaa
.- ~~CL
. ,
Black
Black
Y cOo.
't,
"
"'
Red
:'~1
Blact
. ~
.'"
~
:...
f~
~ ~
ti
~
8'
... "
"'--'
.-
-- -
--
-- --
- -
, - -- - -
- -- -- -
- -
-, -
---
- .
--- -
.-
--
- -'
--
-- . .
.
\
~~;:""'"'
;,'~'"
'y"!e'.
"
~...$,,".-:~.. t'" ~;:-;;. .
.
,
" P. D. I.'L.
,
..-
"
I i.
ENGINEERI.' STIMOAIO
ES : 2001
Selection and -Application of Protective Coaring
-
BARODA. Primers...
..'
SHEET17 o( 19
paiDU shan conformto the foliowi.. IpeeificatioD.
1.
Hip
Builcl Doc Pbospbate Pri8er.
...
Compolitioa
App1icatioa
F"llmTbicbcu
DryiDI tiae
Ziaepbolp... pipC8t8d alkyci/pbcuolic medium. BrDlk or s..". 50mieroaldry per C8L

Hard dry 6-8 .8n ; o..cr coatiD, 16 boan miaimum.
(- .
2.
EpoXJbased primer. Applicati~ TJpe Yixia. Ratio Brushor Spray. Twopeck.cold C8rM. Baseto bardner 3 : 1 by vol.
8 U"'I. 25 mier081 dry per coaL Sarf8Ce dry 2 bo.n. Bard dry 8 boarl. Over eoatin, 16 boun mi.i_a.
~
.i
lire Film ThiCDcu - Oryiac ti-
. lot
ia
3.
~Iorinat-
Rabbet'pai8t
Compos~ O1loriae~eat
Applicau-
Pluticisecl Qleriaat. rubber mediumsuitably piameated. Miaim- IS-/. paiat.
Film Th~::=-~. DryiDI t~

~
40 .icroaa dry
Brush or roBe,.
per ~
.
Bard ory l' boan, 0.. ~li8I 24 bCJ8Tt.
-~
Surfacc ory 2 uun.
'-",---
4.
!wo
pack Epoxy buecI paiDt
.
ar-b or
spraJ. -
epoxy co~
"
MiDim.. W/.
Two pact ceId C8T& Aa per Maaaf8et81W8 recom.C8datio8.
40 _c~
AppIica~
TJpe )tiaiDI raI8
. . . ..
Pot Life
MI.
tki~~-
-.
bo8rs.
DrJiaa t88
s.rfaca
Complete
.,
drJ~
~
~
clays.
- --
---
2 boaR. Bard dry 1.6 boun.
-- S. Silicoa8~ - Appli~ti-
Recoatability-24
C8t'e-7
.'
.
- - -
A.lamiuiu. Pai8t -
-:- - - -~- - -- - ..
Pact.
--- ---
Composi~
-- - -AJamiaiaa -pai81 ~ 08 silicone retia/Sialic

Brush.
:.:...
~
,;
-.. ~ ~'~
"~C~'
-" ,~.,'.,..c
,...:---
"
~--
---~
"," c
";.
.~
c.
P. D- I. L.
ENGINEERINGSTANDARD
Selection and AtPplication of Protective CoatiDI
ES 2001
BARODA. I
SHEET 18OF19
t.
Film Thick-De.s Dryiq time
20 microDl day per coat. 2 hourI at 200-C for co.pletc cure, overcoatiDI 24 hourI at room temperature.
"
6.
Hilb
build micaceous irOD oxide
paiDt
CompoaitioD
:
l , ;
""':
-~
Applic-atioD
--
Micaceous~
oxide/AI..iDiu.
flakc pillDcDted pheDolic medium.
Brush or unCal apra,.

100 microDi dry per coaL
Surface dry 4 hOUR. Bard dry 16 hourI overcoatinl 24 hours miDimum
I
.
(-
/~ 7.
Film TbickDess Dryiul Hip time
i
1
"'-"
Baild Epoxy (two pact)

Epoxy suitably p~CDte4.
MiDimam .SG-/.
- .,..
CompoaitioD Epoxy couteat iD
- ;-1
:j
-.":.,1
Dry fila.
"~:~j
Type. .
AppllQtlOD
Two pact
Bnah or 1prJ.
0'-
:'
ralmnictn~
DryiDa
100 micrO8l "'/~t

Sarface Dl'y-S bo8n
p
~-'*
~-~
~,~..-
Hard Dry-I6' hoan
:;,~'
;::Jj
,Pot Life
aecoatabilfty-24 b..n
Complete curl- 7 days.
1.
i
I
S ~n.
.
a. Heat R.eailtiDl AlumiDiu. Pam.
Co~tj08
i
pia8entM Vamis~ .ediu.~
--=-
AJ8aiDi..
1 ! j
---'"-
. .
Typc Applicalioa
Film Th~aCSl
- - UryiDl time-
Dual pact. Air dryiDI Brusb.

20 micrODl dry per coat~ - ---'_::' ~- --:-:--
Hard drylG- hewn-Recoatability 24 bouR.
h f:;'
.1
-~"'"".~..."
~~-,
,,-
"". .,,"
'~",
\. "i ,~. t.
.
c.
.p D I L. ENGINEERIIG S1 IIDAID
.
I
ES: 2001
BARODA
Selection and. Application
-
SHEET 19 OF 19
,. --
CoalTar Epoxy :
Compolftion
epoxy coateDt ia dry 81m Type
Epoxy/Coal Tar
Minimum 25 ~ 2 pact, coW cured.
.;-.
Application
( ! ,.. .
Brash/Air}.. Spray.
110 microa dry/coat S.rfacc Dry I S boun
'1
I
Film
Dryi..
tbick.ocSi
..
..
Pot life
Hard Dry
Recoatability
- 16 - bourl 24 bouR - 7 days
Complete care S boaR.
I I
10.
Hip
Type
Build Beck litmin Paint Sialic pact Air Dryia,

a..ioforce4 Bitamcn witb Pbcoolic
Compoaitioa ~
Appiicatio8
.
Film ~cbC8
R..iD mcdi.. BruIh. RoUar or Airlna spray

100 to 120 8ier08 dry
1
c.t
Dryi88 Time
-
24 boan depCDdiq 00 cli..tic coaclitiou. to allow 41 to It 72maJ'-M-:aCCCSlary boon iotcrval before apptyiDJ IecoDd ~t. -
--
-.
.r
, \
I
,.
..
.
-
- . -
- . ---
--.
-.. . ..
--
_._.
-
- _.---,- --. .--
--
---
--
-,';:
:lt~
",if.,..
TYPICAL PIPING DRAWING AT EXISTING TAPP-OFF CONNECTIONS
4405-0000-1401 DOCUMENT NO SHEET 1 OF 1
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
P.R.S. PREPD
A.S. REVWD
A.K.S. APPD
4405-0000-1411
PIPELINE SYMBOLS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
P.R.S. PREPD
A.S. REVWD
A.K.S. APPD
4405-0000-1412
TOPOGRAPHICAL SYMBOLS
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
P.R.S. PREPD
A.S. REVWD
A.K.S. APPD
4405-0000-1417
EXISTING UNDERGROUND PIPE CROSSING ( TYPE-II )
NOTES:1. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED; WHERE, THE PIPELINE CROSSES AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID. 2. CONCRETE SLAB SHALL E PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6mm THK. 3. PLASTIC GRATING OR CONC. SLAB NEED NOT TO BE PROVIDED BETWEEN AN EXISTING PIPELINE AND A NEW CASED PIPELINE. 4. SUITABLE CATHODIC PROTECTION BONDING SALL BE PROVIDED BETWEEN CROSSING PIPELINES. IN SOME SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. C.P. DETAIL ARE COVERED SEPARATELY. 5. ALL DIMENSIONS ARE IN mm, UNLESS OTHEWISE STATED. 6. DIMENSION A SHALL BE CALCULATED USING FORMULA A=(D1+D2+..Dn) +( n-1) x 500 WHERE D1, D2, .. Dn 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 PIPELINES LAID IN SAME TRENCH. 8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVANT STANDARDS/SPECIFICATIONS. 9. APPROVAL OF THE CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
P.R.S. PREPD
A.S. REVWD
A.K.S. APPD
4405-0000-1419
UNDERGROUND CABLE CROSSING
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS PREPD
AS REVWD
AKS APPD
4405-0000-1420
OVERHEAD POWER LINE CROSSING
NOTES:1. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456/ PLACTIC GRATING SHALL BE 6mm THICK. 2. SUITABLE MEASURES SHALL BE TAKN FOR THE PROTECTION OF THE LINE AND SECURITY OF PERSONNEL WHEREVER FOUND NECESSARY. 3. ALL DIMENSIONS ARE IN mm, UNLESS OTHERWISE STATED. 4. APPROVAL OF THE CROSSING MAY HAVE TO BE OBTAINED FROM CONCERNED AUTHORITIES. 5. DIMENSION A SHAKK BE CALCULATED USING FORMULA A=(D1+D2+..Dn)+(n-1) x 500. WHERE D1,D2,Dn IS THE DIAMETER OF PIPES LAID IN SAME TRENCH AND n IS NUMBER OF PIPES IN SAME TRENCH.
6. DIMENSION D SHALL BE THE LARGEST DIAMETER OF THE PIPELINES LAID IN SAME TRENCH.
0 REV
18.02.09 REV DATE
18.02.09 EFF DATE
ISSUED PURPOSE
PRS PREPD
AS REVWD
AKS APPD

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GAIL GAS LIMITED

(100% subsidiary of GAIL)

VOLUME- III OF III

PROJECTS & DEVELOPMENT INDIA LIMITED

PROJECTS & DEVELOPMENT INDIA LTD

MASTER TABLE OF CONTENTS

Tender Document No : Description:

PNMM / 4405 / E / 602

PART B PART C PART D

PART E 2) Volume-II OF III 1.0 2.0 3)

Volume-III OF III TECHNICAL SPECIFICATIONS, STANDARDS, SKETCHES, DRAWINGS &

DOCUMENTS FOR CIVIL, PIPING AND ELECTRICAL WORKS.

SPECIFICATIONS, STANDARD & SKETCHES FOR CNG SATATION AT PANVEL

DOCUMENT NO. SHEET 1 OF 3

TABLE OF CONTENTS VOLUME III OF III

MAHARASHTRA OF M/S GAIL GAS LIMITED

Tender Document No. A1.

PNMM / 4405 / E / 602

MECHANICAL PIPING & TUBING SPECIFICATIONS & DRAWINGS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

GREENFIELD MOTHER CNG STATION AT PANVEL M/s GGL

SPECIFICATIONS, STANDARD & SKETCHES FOR CNG SATATION AT PANVEL

DOCUMENT NO. SHEET 2 OF 3

VOLUME III OF III Sl. Description Doc. No.

GREENFIELD MOTHER CNG STATION AT PANVEL M/s GGL

SPECIFICATIONS, STANDARD & SKETCHES FOR CNG SATATION AT PANVEL

DOCUMENT NO. SHEET 3 OF 3

VOLUME III OF III

PIPELINE STANDARD AND SKETCHES

ELECTRICAL (Drawings / Standards)

GREENFIELD MOTHER CNG STATION AT PANVEL M/s GGL

PROJECTS & DEVELOPMENT INDIA LIMITED

SPECIFICATION FOR EXCAVATION OF THE TRENCH

18.02.09 REV DATE

18.02.09 EFF DATE

SIGNALLING, FENCING AND LIGHTING SIGNALLING

12.1.1 Site Identification

PROJECTS & DEVELOPMENT INDIA LIMITED

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

18.02.09 REV DATE

18.02.09 EFF DATE

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

During job execution

Facilitate PDIL/Owner in the quality audit at his works.

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

STANDARD SPECIFICATION FOR QUALITY ASSURANCE SYSTEM

TYPE (APPROVAL) SURVEILLANCE

PROJECTS & DEVELOPMENT INDIA LIMITED

18.02.09 REV DATE

18.02.09 EFF DATE

4405-PNMP-TS-0905 DOCUMENT NO SHEET 2 OF 6

4.1 4.2 4.3 5.0 6.0 7.0 8.0

4405-PNMP-TS-0905 DOCUMENT NO SHEET 3 OF 6

TAKING OVER PIPES AND PIPELINE ACCESSORIES

4405-PNMP-TS-0905 DOCUMENT NO SHEET 4 OF 6

25mm 32mm 50mm 80mm

4405-PNMP-TS-0905 DOCUMENT NO SHEET 5 OF 6