KG-DWN-98/2 PRE-FEED

Piping Material Specification

Level 18, Menara AIA Cap Square

No. 10 Jalan Munshi Abdullah
Kuala Lumpur 50100
Malaysia

Document No.: 402020-01391-08-PI-SPC-0001

Revision :0
Date : 20 Oct 2016

www.intecsea.com
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HOLDs List

HOLDs to be inserted in the following table.

HOLDS closed during following revision of document to be deleted from the table.

HOLDs Section No. Description of HOLDS

No. & Revision
Inserted

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Table of Contents
1 INTRODUCTION ................................................................................................................... 6

1.1 Project Overview..................................................................................................... 6

1.1.1 Odalarevu Facilities............................................................................................... 7

1.2 Industry Codes ........................................................................................................ 8

1.3 Standards ................................................................................................................ 10

1.4 Reference COMPANY Functional Specification ......................................... 11

1.5 Local Government Regulations ....................................................................... 11

1.6 Definitions ............................................................................................................... 12

1.7 Abbreviations and Acronyms ........................................................................... 13

2 GENERAL ............................................................................................................................... 17
3 DESIGN CRITERIA ............................................................................................................... 18

3.1 Corrosion Allowance ........................................................................................... 18

3.2 Piping Sizes and Rating...................................................................................... 18

3.3 Piping Selection .................................................................................................... 18

3.4 Valves Selection .................................................................................................... 19

3.5 Flanges ..................................................................................................................... 19

3.6 Spectacles Blind, Spades and Spacer ............................................................ 19

3.7 Fittings...................................................................................................................... 20

4 MATERIAL ............................................................................................................................. 21

4.1 General ..................................................................................................................... 21

4.2 Carbon Steel........................................................................................................... 21

4.3 Carbon Steel (Galvanised) ................................................................................. 22

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4.4 Stainless Steel ........................................................................................................ 22

4.5 Glass Reinforced Epoxy (GRE) .......................................................................... 23

5 GASKET .................................................................................................................................. 24

6 BOLTING ................................................................................................................................ 25

7 MATERIAL CERTIFICATION ............................................................................................. 26

8 OTHER REQUIREMENTS .................................................................................................. 28

8.1 Low Temperature Service .................................................................................. 28

8.1.1 Material for Low Temperature Service ........................................................28

8.1.2 Piping Fabrication for Low Temperature Service ....................................29

9 PIPING MATERIAL CLASSIFICATION ........................................................................... 30

9.1 Piping Material Specification ........................................................................... 30

10 APPENDICES......................................................................................................................... 31

App Appendix List

Appendix 1: List Of Applicable Piping Material Classification ................................................................... 33

Appendix 2: Glass Reinforced Epoxy (GRE) ....................................................................................................... 34

List

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1 INTRODUCTION

1.1 Project Overview

ONGC intends to develop the NELP block KG-DWN-98/2, in deep waters off the east coast of India.
The discovery areas in the block have been categorized as Northern Discovery Area (NDA) and
Southern Discovery Area (SDA). At present, the scope for development only covers NDA.

The KG-DWN 98/2 block is located within 25-40 km of the nearest land-fall, and is adjacent to RIL’s
KG-D6 field and GSPC’s Deendayal field. The water depth in this block varies between 300 metres
and 3,200 metres.

A location map identifying the KG-DWN 98/2 development area is presented as Figure 1.1.

Figure 1.1: Location map of KG-DWN 98/2

The fields discovered in the area comprise of a number of oil and gas discoveries, and are spread
over a large area. Each field has technical challenges such as high wax, hydrates, sand production
and high pressure / high temperature.

The NDA is estimated to contain 121 Million Te (1,000 Million BBL @ SG 0.7) of initial oil in place
and 78 BCM (2.8 TCF) of initial gas in place spread over seven fields, which was established through
4,769 sq. km of 3D API and drilling of 20 exploratory / appraisal wells.

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The NDA Cluster 2 covers the following production area:

Mix of oil and gas, located in the south of NDA, includes the following fields :

Oil fields (Cluster 2A) - A2, P1, M3, M1, M4 and G-2-2.

Gas fields (Cluster 2B) - R1, U3, U1, and A1.

1.1.1 Odalarevu Facilities

There is an existing terminal at Odalarevu, and coordinates for the existing G-1 “straight” 10”
export flowline shore crossing is shown in Figure 1.2.

Figure 1.2: Odalarevu Terminal and 10” Pipeline Shore Crossing

Note the coordinates are based on Everest 1830, UTM Zone 44.

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1.2 Industry Codes

Item No. Code Number Description

1. API 5L Specification for Line Pipe

2. API 6D Pipeline Valves

3. API 6FA Fire Test for Valves

Recommended Practice for Design and Installation of

4. API 14E
Offshore Production Platform Piping System

Design and Installation of Pressure Relieving System in

5. API 520
Refineries

6. API 521 Guide for Pressure Relief and Depressurizing System

7. API 526 Flanged Steel Safety Relief Valves

8. API 553 Refinery Control Valves

9. API 590 Steel Line Blanks

10. API 594 Wafer and Wafer Lug Check Valves

11. API 598 Valve Inspections and Test

12. API 600 Steel Gate Valves – Flanged and Butt Welding Ends

13. API 601 Metallic Gaskets for Piping

14. API 602 Compact Carbon Steel Gate Valves

15. API 607 Fire Test for Soft Seated Ball Valves

16. API 608 Metal Ball Valves: Flanged, Threaded & Welding End

17. API 609 Butterfly Valves: Double Flanged, Lug & Wafer Type

Centrifugal Pumps for Petroleum, Petrochemical and

18. API 610
Natural Gas Industries

19. API 661 Air-cooled Heat Exchangers for General Refinery Services

Axial and Centrifugal Compressors and Expander-

20. API 617
compressors

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Item No. Code Number Description

Special Purpose Couplings for Petroleum, Chemical and
21. API 671
Gas Industry Services

Positive Displacement Pumps - Controlled Volume for

22. API 675
Petroleum, Chemical, and Gas Industry Services

23. ASME B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

24. ASME B1.20.1 Pipe Threads, General Purposes

Pipe Flanges and Flanged Fittings, Steel, Nickel Alloys and

25. ASME B16.5
other Special Alloys

26. ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

Face to Face and End to End Dimensions of Ferrous

27. ASME B16.10
Valves

28. ASME B16.11 Forged Steel Fittings, Socket Welding and Threaded

Metallic Gaskets for Pipe Flanges, Ring Joint, Spiral

29. ASME B16.20
Wound and Jacketed

30. ASME B16.21 Non-Metallic Flat Gaskets for Pipe Flanges

31. ASME B16.25 Butt Welding Ends

32. ASME B16.34 Valves – Flanged, Threaded and Butt Welding Ends

33. ASME B16.36 Steel Orifice Flanges

34. ASME B16.47 Large Diameter Steel Flanges NPS 26” through NPS 60”

35. ASME B18.2.1 Square and Hexagonal Bolts & Screws

36. ASME B18.2.2 Square and Hexagonal Nuts

37. ASME B 31.3 Process Piping

38. ASME B 31.8 Gas Transmission and Distribution Piping Systems

39. ASME B36.10 Welded and Seamless Wrought Steel Pipe

40. ASME B36.19 Stainless Steel Pipe

41. ASME Sec V Non-Destructive Examination

42. ASME Sec VIII Div.1 Rules for Construction of Pressure Vessels

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Item No. Code Number Description

Qualification Standards for Welding and Brazing
43. ASME Sec IX Procedures, Welders, Brazers and Welding and Brazing
Operators

Specification for Pipe, Black and Hot Dipped Zinc Coated,

44. ASTM A53
Welded and Seamless.

Standard Specification for Forgings, Carbon Steel, for

45. ASTM A105
Piping Components.

Standard Specification for Seamless Carbon Steel Pipe for

46. ASTM A106
High. Temperature Service.

Specification for Alloy-Steel and Stainless Steel Bolting

47. ASTM A193
Materials for High Temperature Service.

Specification for Carbon and Alloy Steel Nuts for Bolts for
48. ASTM A194
High-Pressure and High-Temperature Service.

Specification for Piping Fittings of Wrought Carbon Steel

49. ASTM A234
and Alloy Steel for Moderate and Elevated Temperatures.

Standard Specification for High-Strength Bolts for

50. ASTM A325
Structural Steel Joints.

51. AWS D1.1 American Welding Specification

52. BS-EN-10204 Metallic Products – Type of Inspection Documents

1.3 Standards

Item No. Standard Number Description

1. IS 1870 Comparison of Indian and Overseas Standards

2. IS 1978 Line Pipe

3. IS 1979 High Test Line Pipe

Steel Plates for Pressure Vessels used at Moderate and

4. IS 2041
Low Temperature

5. IS 2379 Colour Code for Identification of Pipelines

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Item No. Standard Number Description

6. IS 2825 Code for Unfired Pressure Vessels

7. IS 3114 Code of Practice for Laying Pipes

8. IS 3589 Seamless or ERW Pipes (150 NB to 2000 NB)

9. IS 4853 Radiographic Examination of Butt Weld Joints in Pipes

10. IS 4864 to 4870 Shell Flanges for Vessels and Equipment

11. IS 5312 Specification for Check Valves

12. IS 6157 Inspection and Testing of Valves

13. IS 6392 Steel Pipe Flanges

14. IS 7719 Metallic Spiral Wound Gaskets

15. IS-10605 Steel Globe Valves for Petroleum Industry

16. IS 10611 Steel Gate Valves for Petroleum Industry

17. IS 10989 Cast/Forged Steel Check Valves for Petroleum Industry

18. IS-11792 Steel Ball Valves for Petroleum Industry

1.4 Reference COMPANY Functional Specification

Functional Specification
Item No. Description
Number

1. 2007A Onshore Piping Design

2. 2007E Welding and NDT for Piping

3. 2008 Piping Material Specification

4. 2009F Functional Specification for Welding and NDT

5. 2009F Addendum for Welding of Duplex Stainless Steel

1.5 Local Government Regulations

Item No. Description

1. Indian Electricity Act & Rules 1956

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Item No. Description

2. Mines Act DGMS 1956

3. Factory Act

4. APSEB – Andra Pradesh State Electricity Board Directives, Rules and Regulations

5. IEE Regulation for Electrical Equipment

6. Electrical Safety Code – Institute of Petroleum (UK)

7. Petroleum Rules 1976

1.6 Definitions

Term Definition
COMPANY or “Owner” shall mean ONGC, its affiliated companies, partners, co-
COMPANY lessees, co-owners, joint ventures, and their agents, third party inspectors,
officers, and employees.

Where referenced shall mean COMPANY’S written and executed contract with
CONTRACT
the CONTRACTOR.

Also referred to as “Vendor”, “Seller” or “Supplier” shall mean the party to

CONTRACTOR whom COMPANY’S Purchase Order, Work Order, or other written CONTRACT is
awarded.

Where referenced, shall mean those processes that produce the equipment,
Construction
including manufacture, fabrication, assembly, and testing.

May Indicates possible course of action.

Safety Critical Any assembly or sub-assembly deemed to be critical to the safety, integrity and
Element performance of the subsea production system.

Shall Indicates mandatory requirement.

Should Indicates preferred course of action.

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Term Definition
The person, group or organization who may be employed by CONTRACTOR (or
subcontractor in reference to a supply chain) to provide services for the design,
Sub-Contractor manufacture, testing and load-out / shipping of the equipment, or, to provide
materials, sub- components and sub-assemblies for incorporation in the
specified equipment.

Will Indicates an intention of action.

Work The scope of work to be performed per the CONTRACT.

1.7 Abbreviations and Acronyms

Term Definition
ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

ATM Atmospheric

B/B Bolted Bonnet

BBE Bevel Both End

BDV Blowdown Valve

BE Bevel Ended

BLE Bevel Large End

BS British Standards

BW Butt Welded

CA Corrosion Allowance

Calc Calculate

Comp Compression

CPL Coupling

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Term Definition
Cr Chromium

CRA Corrosion Resistant Alloys

CS Carbon Steel

Cu Copper

DB&B Double Block and Bleed

DSAW Double Submerged Arc Welded Electric

ERW Electric Resistance Weld

EFW Electric Fusion Weld

F/F Face to Face

FF Flat Face

FLG Flange

FO Fully Open

GALV Galvanized

Gr Grade

HF Hard Faced

HW Hand Wheel

Lb Pounds Force

LCS Low Carbon Steel

L.J. Lap Joint

FM Factory Mutual

KSC Kilogram Per Square Centimeter

MEG Mono Ethylene Glycol

M.I. Malleable Iron

MSS Manufacturers Standardization Society

NACE National Association of Corrosion Engineers

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Term Definition
Ni Nickel

NPS Nominal Pipe Size

NPT National Pipe Thread

OS&Y Outside Screw and Yoke

NACE National Association of Corrosion Engineers

OISD Oil Industry Safety Directorate

ONGC Oil and Natural Gas Corporation

P&ID Piping & Instrumentation Diagram

PMS Piping Material Specification

PSV Pressure Safety Valve

PBE Plain Both Ends

PE Plain Ends

PSI Pounds per Square Inch

PSIG Pounds per Square Inch Gauge

RF Raised Face

RTFE Reinforced Teflon

RTJ Ring Type Joint

SAW Submerged Arc Welded Tubular

Sch Schedule

SCRD Screwed Fitting

SDV Shut Down Valve

SMLS Seamless

SO Slip On

SS Stainless Steel

STD Standard Wall Thickness

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Term Definition
SW Socket Welded

TBE Threaded Both Ends

TSE Threaded Small End

WE Weld End Valve

WN Welding Neck

Wt Weight

WT Wall Thickness

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2 GENERAL
All piping system shall conform to ASTM or BS Standard and shall be designed according to either
ASME B31.3 (Based on P& ID). Piping Material Classification shall be as per Appendix A.

Metallic pipe shall be specified with the nominal size and schedule as per ASME B36.10/ B36.10M
and ASME B36.19/ B36.19M

The post weld heat treatment (PWHT) for pipe and fittings shall be as per ASME B31.3 requirement.

Except under special conditions of severity, hazard, etc., the materials used shall be in accordance
with the Piping Material Specifications, which are based on the design pressure and temperature
and on the type of service. The materials used under special conditions of severity and hazard must
be suitable for the particular service conditions involved.

Thickness for butt welding fittings shall be same as that of corresponding pipe. Short radius
elbows, which have been de-rated as specified above, may require a wall thickness greater than
that of the connecting pipe.

All gaskets and packing shall be asbestos free.

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3 DESIGN CRITERIA

3.1 Corrosion Allowance

Unless otherwise specified on the Pipe Specification Index & other project specification, corrosion
allowance shall be as following;

a) Carbon steel pipes shall have 3 mm corrosion allowance.

b) Carbon steel (NACE) shall have 6 mm corrosion allowance,

When corrosion protection is provided by a corrosion resistant metallic lining, a minimum

thickness of 3 mm of lining material shall be used.

3.2 Piping Sizes and Rating

Nominal pipe sizes DN 32 ( 1 ¼”), DN65 (2 ½”), DN85 (3 ½”) and DN125 (5”) shall not be used
except where they are required for connection to equipment of standard design or where specific
velocities must be maintained. When the sizes are used on equipments, the connecting piping shall
be increase or decreased to standard sizes as close to equipment as practical. Using such
components shall be subjected to COMPANY approval.

Unless otherwise specified, pressure ratings for piping components shall normally be in accordance
with ASME B16.5. In general, the following pressure ratings shall only be used: Class 150, 300, 600,
900 and 1500. Other pressure ratings shall not be used except when specified in P&ID or when
required for equipment connections. Piping components not covered by the piping material
classification shall be approved by COMPANY.

3.3 Piping Selection

Pipe dimension and tolerances shall be in accordance with ASME B36.10/ B36.10M for carbon steel
pipe and ASME B36.19/ B36.19M for Stainless Steel Pipe. Cu-Ni (90/ 10) shall be in accordance with
BS2871 Part 2. up-to DN 500 (20”)

All carbon steel pipes shall be seamless upto 16”. Above 16” pipes shall be SAW with 100%
radiography.

All 90/10 Cu-Ni pipes shall be seamless upto 16”. Above 16” pipes shall be EFW with 100%
radiography.

All stainless stess piping upto 8” shall be seamless. Above 8” shal be EFW with 100% radiography.

All pipes shall have bevel end for sizes equal to and above 2” and plain end below 2” diameter.

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Pipe wall thickness shall be confirmed by calculation in accordance with code requirement, i.e.
ASME B31.3. Minimum wall thickness of carbon steel and low alloy pipes, including corrosion
allowance shall be as following;

a) DN 40 ( ½”) or less – schedule 80

b) DN50 (2”) through DN150 (6”) – schedule 80

c) DN200 (8”) through DN600 (24”) – standard wall

3.4 Valves Selection

Valves shall be provided in accordance with the Valve Material Selection (Doc. No. 4020-01391-08-
PI-0002).

3.5 Flanges
Dimension and tolerances of flange shall be in accordance with ASME B16.5 for all flange sizes up
to DN600 (NPS 24) and ASME B16.47 Series A or MSS SP-44 for sizes DN650 (NPS 26) and above.
Inside diameters of weld neck flanges shall generally be equal to those of connecting pipe.

Raised Face Flanges have been specified for all piping classes up to and including ASME Class 600.

Flanges shall be RTJ type for rating above #600. RTJ flange shall have octagonal grooves
conforming to ASME B16.5

Smooth finish on flanges shall be 125 AARH.

Wherever face finish is not mentioned, it shall be serrated spiral/ concentric.

3.6 Spectacles Blind, Spades and Spacer

The used blinds, spades and spacers shall strictly follow the location indicated on P&ID and shall
meet the requirements of ASME B16.48.

The material shall be from the material group specified in the applicable pipe class. For example,
for pipe class A, the Material Group is 1.1. Material generally shall be “plate” (i.e., SA-516 Gr. 70 for
Material Group 1.1). However, forgings are acceptable as well.

For sour service, hardness must not exceed the limits specified in NACE MR0175 / ISO 151565.

Material thicker than 50 mm (2”) shall be normalised, or impact tested materials shall be used to
retain the minimum design metal temperature of the applicable Pipe Class.

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Spades and spacers shall be used in lieu of spectacle blinds when the pipe sizes in the following
table are exceeded;

ASME Flange Class Nominal Diameter (DN)/ NPS

150 DN 350 / 14”

300 DN 300/ 12”

600 DN 300/ 12”

3.7 Fittings
Dimensions of metallic fittings shall be in accordance with ASME B16.11 for threaded and socket
welding fittings and ASME B16.9, MSS SP-97, MSS SP-75 for butt welding fittings. Wall thickness
of butt welding fittings shall not be less than the minimum specified wall thickness of connecting
pipe.

Short radius (SR) elbow shall not be used unless absolutely required for clearance purpose with
prior approval from COMPANY. If short radius elbows are used, they shall be de-rated to 80% of
the calculated allowable working pressure if subjected to pulsations.

Reducing elbows shall not be used, except as Specialty Piping (SP) items.

Welded end closures shall be made using welding caps. However, consideration shall be given to
flushing and pressure testing before employing caps. Manifolds shall have blind flange ends with
taps and valves for flushing, venting, pressure instruments, etc.

Nipples for screwed connections in valves, piping accessories or equipment shall be as a minimum
Schedule 160 for carbon steel and Schedule 40S for Stainless Steel.

Branch Connections using welding tees or commercial integrally reinforced fittings such as
weldolets, sockolets (forged only) or socketweld couplings are equally acceptable, with the choice
of the type of connection based on the criteria provided by the Branch Connection Tables
contained in Appendix A.

Stub-in connections shall not be used unless with prior approval from the COMPANY

Mitre joints shall not be used.

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4 MATERIAL

4.1 General
All material used shall be in accordance with code requirements and industry standards for good
workmanship.

For services (i.e., temperatures, pressures, fluid compositions and properties) not explicitly included
in the Pipe Classes, consult with a materials engineer and piping engineer to obtain a suitable
Piping Specification.

Cast, ductile or malleable iron, aluminium, copper, or copper-bearing alloys shall not be used in
hydrocarbon service.

4.2 Carbon Steel

Carbon Steel material used and specified in accordance with American specifications.

Pipes ASTM A 106 Gr. B (seamless), API 5L Gr. B (seamless / SAW),

API 5 L Gr. X 52 (Seamless/SAW), API 5L Gr. X 60 (Seamless / SAW)

Fittings ASTM A 234 Gr. WPB, ASTM-A105,

MSS SP Gr. WPHY 52 MSS SP Gr. WPHY 60

Flanges ASTM A105, ASTM A694 Gr. F52,

API 6A Type 2, API6A Type 4

Valves Body- ASTM 216 GR WCB, ASTM A 105

Trim- 11-13% CHROME (MIN.)/ ASTM 182 GRADE F316

Bolts/ Nuts ASTM A193 Gr. B7 (Galvanised per ASTM ASTM A153)
Nuts: ASTM A194 Gr. 2H (Galvanised per ASTM ASTM A153)

Low temperature service requirement shall be in compliance with Section 8.1 of this document.

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4.3 Carbon Steel (Galvanised)

All pipe fittings specified as galvanized shall be hot dip galvanized with a minimum of 763 grams
of galvanizing material per square meter of surface area, in accordance with ASTM A123M/ASTM
A153.

Pipes For sizes 0.5” to 2.0” : ASTM A312 TP316 (Screwed)

For sizes 3.0” and larger : ASTM A106 Gr B (Galvanized)

Fittings For sizes 0.5” to 2.0” : ASTM 182 F316 (Screwed)

For sizes 3.0” and larger : ASTM A234 Gr WPBI

Flanges ASTM A105 (Galvanised)

Valves Body, Bonnet, Trim : ASTM B61 (Leaded tin Bronze) Stem, Wedge disc, Body seat
ring – Forged Brass as per ASTM B124 C37700 (No casting)

Bolt/ Nuts Bolt: ASTM A307 Gr B (Galvanised as per ASTM A123M/ ASTM A153)
Nut: ASTM A563 Gr. B (Galvanised as per ASTM A123M/ ASTM A153)

4.4 Stainless Steel

Stainless steel materials are suitable for inner/wet parts of valves, instrumentation & vessels. Only
following American specifications as specified against each product are permitted.

Pipes ASTM A312 Gr. TP316/ 316L

ASTM A 358 TP 316/ 316L

Fittings ASTM A403 Gr. WP 316/ 316L

ASTM A182 Gr. F316/ 316L

Flanges ASTM A182 Gr. F316/ 316L

Valves Body: ASTM A182 Gr. F316L/ ASTM A351 Gr. CF8M SS316L
Trim: ASTM A182 Gr. F316/ 316L

Bolt/ Nuts Bolt: ASTM A193 Gr.B7M (22 HRC max. hardness)
Nut: ASTM A194 GR 2M (22 HRC max. Hardness)

Note:

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For all austenitic stainless steel piping, piping components and valves, Intergranular Corrosion Test
(IGC) shall be conducted as per following ASTM A 262 practice “B” with acceptance criteria of 60
mills per year (max) for all materials forged, rolled, wrought and casting.

OR

ASTM A 262 practice “E” with acceptance criteria of “No cracks as observed from 20X
Magnifications” for all materials other than castings “Microscopic structure to be observed from
250-X magnification” in addition.

4.5 Glass Reinforced Epoxy (GRE)

GRE piping material shall comply with requirements given in Appendix 2

Valve material for GRE piping shall be suitable to services for which GRE piping is used.

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5 GASKET
Ring joint, spiral wound and jacketed gaskets for installation between flanges in piping systems
shall meet the requirements of ASME B16.20, Metallic Gaskets for Pipe Flanges.

Sheet gaskets for installation between flanges in piping systems shall meet the requirements of
ASME B16.21, Non-metallic Flat Gaskets for Pipe Flanges

As a general rule, the gasket inside diameter shall not extend beyond the inside diameter of the
flange’s bore i.e. gasket diameter shall match the bore of the flange and shall not restrict the flow
of the process fluids and/or gas.

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6 BOLTING
Flange bolting shall be provided in accordance with the Piping Material Specification for the
applicable Piping Class Rating and Service.

Materials for use below -45.6°C and above 593°C shall be approved in writing by OWNER unless
otherwise specified in supplementary specifications.

Studs shall be threaded full length.

Threads on stud bolts and nuts under 1” diameter shall be coarse thread series. Larger diameter
studs shall have Unified 8 Class 2A threads. Nuts shall have Class 2B threads.

Unless flange bolts will be tightened using hydraulic bolt tensioning, the stud length shall be
selected such that when nuts are fully engaged the stud projects beyond the nuts by not more
than two full threads. Stud length for ASME B16.5 flange to flange connections shall be in
accordance with lengths indicated in the applicable tables of ASME B16.5. When flange bolts will
be tightened using hydraulic bolt tensioning, the stud length shall have provision of a minimum of
one( 1) thread and a maximum of three (3) threads outside each nut and complete with 2 nuts such
that the stud on the tensioner side protrudes at least one nut thickness beyond the nut.

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7 MATERIAL CERTIFICATION
The manufacturer shall provide certification to verify that the materials of construction meet the
requirements of the material specifications. All certificates shall be original or verified by 3rd party.

Generally all certificates shall contain the following information; however more information may
needed according to service requirements.

a) Name of manufacturer

b) Purchaser order number and date

c) Manufacturer’s order number

d) Identification number of certificate and its date of issue

e) Material specifications

f) Dimensions

g) Material charge number, batch number or heat-lot number

h) Mechanical properties recorded from chemical analyses

i) Non-Destructive Test methods and results, where applicable

j) Heat treatment procedures and records, where applicable

The different types of inspection certificate;

a) Inspection Certificate 3.1 “type 3.1” (BS EN 10204)

Document issued by the manufacturer in which he declares that the products supplied are in
compliance with the requirements of the order and in which he supplies test results

b) Inspection Certificate 3.2 “type 3.2” (BS EN 10204)

Document prepared by both the manufacturer’s authorized inspection representative,

independent of the manufacturing department and either purchaser’s authorized inspection or
the inspector designated by the official regulations and in which they declare that the products
supplied are in compliance with the requirements of the order and in which test result are
supplied.

As a minimum, material certificates in accordance with Type 3.1 are required for Carbon Steel
pressure-containing parts in non-hydrocarbon services (air and water only) with an operating
o
temperature above 0 C.

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Material certificates in accordance with Type 3.2 are required for pressure-containing piping,
fittings, valves, gaskets and bolting in hydrocarbon service, which are manufactured from
carbon steel, low and high alloy steel (martensitic steels, ferritic stainless steel, austenitic
stainless steel, duplex stainless steel), nickel alloy steels (copper-nickel, Monel, Inconel, Incoloy,
nickel aluminum bronze etc.) and titanium.

Marking is required for all component parts certified under material certificates Type 3.2;

a) Parts with wall thickness above 5 mm, except items made of stainless steel of nickel alloys,
shall be legibly maked by low pressure hard-die stamping on to a painted background,
and at a point clearly visible later.

b) Item made of stainless steel or nickel alloys and parts with wall thickness below 5 mm shall
be marked by stencil with a water insoluble ink without metallic pigments, sulphur,
sulphides or chlorides which could harmfully affect the material.

The stamping/ marking shall, where applicable, include the following;

a) Manufacturer’s symbol
b) Material and product identification
c) Charge or batch number
d) Heat treatment chart or furnace charge reference number, where applicable
e) Heat treatment symbol or code, where applicable
f) NDT symbol or code, where applicable
g) Size and schedule
h) Hydrostatic test pressure, where applicable

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8 OTHER REQUIREMENTS

8.1 Low Temperature Service

Services / environments with a minimum design metal temperature below -29°C shall be defined
as low temperature.

The design of piping with design temperature outside the scope of this specification but exposed
to ambient temperatures below -29°C for long periods must take into account the possibility of
brittle failure if one of the following conditions exists:

a) Piping is in intermittent service and is under pressure when there is no flow in the system.
b) There can be coincident high pressure and low pipe metal temperature (less than -29°C) on
start-up.

8.1.1 Material for Low Temperature Service

All materials used in the construction of a piping system operating below -29°C shall conform to
the requirements of ASME B31.3.

Packaged refrigeration piping may conform to either ASME B31.3 or ASME B31.5.

All material used in the construction of the piping system shall be Charpy Impact tested in
accordance with ASTM Standards and ASME B31.3.

Corrosion allowance shall be 6.0 mm for sour, low temperature service. No corrosion allowance is
required for stainless steels in sweet or sour service.

The following materials are suitable for low temperature service:

a) ASTM A-312 Seamless and Welded Austenitic Stainless Steel Pipe

b) ASTM A-193 or, when appropriate A-320
c) ASTM A-333 Specification for Low Temperature Steel Pipe
d) ASTM A-334 Seamless and Welded Steel tubes for Low Temperature Service
e) ASTM A-350 Forged or Rolled Carbon and Alloy Steel Flanges, Forged Fittings, and Valves and
Parts for Low Temperature Service
f) ASTM A-420 Welding Fittings for Low Temperature Service

Where A-333 Grade 6 is specified for cryogenic service, A-312 may be used as a suitable
alternative.

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8.1.2 Piping Fabrication for Low Temperature Service

All welds in low temperature service shall be stress relieved and radiographed as per the
following;

ASME Class PWHT Radiography

150 Yes (Thickness less than 19 mm may be 5% of all butt welds to be 100%
exempt by selecting “as welded” radiographed
procedures which are impact tested to
minus (–) 45.6ºC)

300 Yes (Thickness less than 19 mm may be 10% of all butt welds to be 100%
exempt by selecting “as welded” radiographed
procedures which are impact tested to
minus (–) 45.6ºC)

600 Yes (For non-vibrating service, thickness 10% of all butt welds to be 100%
less than 19 mm may be exempt by radiographed
selecting “as welded” procedures which
are impact tested to minus (–) 45.6ºC)

Welding after stress relieving is not permitted.

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9 PIPING MATERIAL CLASSIFICATION

9.1 Piping Material Specification

The piping material specification is prepared based upon Functional Specification FS 2007A, FS
2008 and Piping Design Criteria giving minimum indicative piping thickness, material of
construction, fittings, gaskets and bolts etc.

CONTRACTOR shall develop piping material specification and valve material specification and
provide all supporting documents including piping wall thickness reports, material selection basis
etc. during detail engineering. If it is observed that certain specification sheets are required as per
approved P&ID but not included in this document, EPC contractor shall prepare the same based
upon FS 2007A and FS 2008. EPC contractor shall submit it to company's review and approval.

Piping and Valve material specification for non-metallic piping is not included in this document
and contractor shall prepare the same based upon vendor information as per manufacturer
standard.

Valve tag nos. indicated in the PMS is for reference only. CONTRACTOR shall prepare detail valve
material specification based on FS 2007A, FS 2008 and other relevant codes. Contractor shall
reconfirm the tag nos. indicated in the Piping material Specification.

Flange gasket surfaces for spiral wound gaskets shall be “smooth” i.e. serrated-spiral finish shall be
formed by a 0.8 mm radius round nose tool at a feed rate between 0.35 mm and 0.45 mm per
revolution. This shall result in a surface roughness between Ra 3.2 and 6.3 micrometers in
accordance with ASME B46.1.

Bolting shall conform to ASME B18.2.1 and the relevant ASTM standards. Nuts shall conform to
ASME B18.2.2. All stud bolts and nuts shall be hot dipped galvanized or electrogalvanized.

Flange bolting shall be a full threaded alloy steel stud bolt, each with two (2) heavy hexagonal nuts.
Stud bolts shall have full continuous threads and have lengths in accordance with B16.5 with the
provision that a minimum of one (1) thread and a maximum of three (3) threads outside each nut
and complete with two (2) nuts. Hydraulic bolt tensioning shall be applied for bolt diameter larger
than and inclusive 1.5 inch.

All 90º-weld elbows shall be long radius, unless restricted by available space. Short radius (SR)
welding elbows shall not be used unless absolutely required for clearance purpose with prior
approval from COMPANY.

List of applicable Piping Material Specification (PMS) are attached in Appendix A.

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10 APPENDICES
APPENDIX A : LIST OF APPLICABLE PIPING MATERIAL SPECIFICATION

PMS Code ASME Class Material Corrosion Service Application

Allowance

A1 #150 CS 3.0 mm (BD) – Blow-Down

(DF – Diesel Fuel
(DH) – Drain Hydrocarbon
(DW) – Drain Water, etc.
(FG) – Fuel Gas
(FL) – Flare
(N) – Nitrogen
(P) - Process Liquid & Vapours
(SV) – Safety Valve Discharge

A1L #150 LTCS 3.0 mm (BD) – Blow-Down

(DH) – Drain Hydrocarbon
(FL) – Flare

A3 #150 SS-316L 0.0 mm/ (AI) – Instrument Air

CS- Galvanized 3.0 mm (AU) – Utility Air

A3S #150 GRE 0.0 mm/ (WF) – Fire Water

(Underground)
(DW) – Drain Water
(Underground)

A6 #150 SS-316L 0.0 mm/ (FG) – Pilot Gas, Ignition Gas

A8 #150 CS Galvanized 3.0 mm (WF) – Fire Water

(WP) – Potable Water

B1 #300 CS 3.0 mm (FL) – Flare

B2 #300 CS 1.5 mm (T) Hot Oil

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D1 #600 CS 3.0 mm (P) - Process Liquid & Vapours

(BD) – Blow-Down
(DH) – Drain Hydrocarbon
(FG) – Fuel Gas

E1 #900 CS 3.0 mm (P) - Process Liquid & Vapours

(FG) – Fuel Gas

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Appendix 1: List Of Applicable Piping Material

Classification

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Appendix 2: Glass Reinforced Epoxy (GRE)

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1.0 SCOPE

This specification contains minimum requirements for design, manufacture, qualification,

quality control, testing, site fabrication, installation and certification of (GRE) composite
piping material.

2.0 DESIGN / OPERATING DATA

The design / operating data such as pressure, temperature, flow rate, structural load, etc.
shall be provided by the user section or the selection / design of GRE piping for the
relevant services.

3.0 DESIGN & MANUFACTURE OF GRE PIPING

a) The piping and fittings shall be manufactured with epoxy resin as per ASTM D 2996
with thickness to suit the design pressure, taking into account the hydrostatic test
pressure at the time of installation i.e. 1.5 times the design pressure. The
manufacturer shall give full details of this methodology of arriving at the quoted
thickness, including lower confidence limit static (LCLs). The hydrostatic design
stress shall be calculated as : 0.5 X LCLs. However, all the components of piping
system shall have minimum 3.0 mm reinforced wall thickness. The fire water piping
system shall also be designed for blast over pressures.

b) The piping and fittings shall be manufactured by using epoxy resin and the
structural glass fiber shall be E-glass. The fittings shall be manufactured by the
same piping manufacturer and compatible adhesives shall also be supplied by the
manufacturer

c) Inner surface of piping and fittings shall have at least 0.5 mm thick reinforced resin
rich liner with C-glass or synthetic fibres and with resin content at least 65%.

d) For UV protection, UV stabilizer will be added in the resin used for manufacturing
GRE piping

e) Filler shall not be used in the resin during manufacturing process of GRE piping.

f) The piping and fittings shall be joined by the bell & spigot joint using adhesives or
butt and wrap joint.

g) Flanges shall be heavy-duty filament wound as per ASTM D 4024 and ASME B16.5.

h) Stress analysis shall be carried out for estimation of stresses in circumferential and
longitudinal direction. Stress analysis shall include, but not limited to, all anchors,
guides and supports. The piping system shall be designed in such a way to
minimize stresses resulting from surge or transient pressures on account of valve
closures or other condition resulting in charge in fluid velocity and those resulting

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from movements such as expansion and contraction from pressure and

temperature differences.

i) Epoxy resins and additives used in the manufacture of potable water piping and
fittings shall satisfy the requirements of FDA / NSF / WHO or other Indian
regulatory Authorities for potability of water

4.0 QUALIFICATION & QUALITY CONTROL OF GRE PIPING

a) The piping and fittings shall be qualified for pressure rating as per ASTM D2992.
Manufacturer shall enclose the test report and calculations.

b) For quality control, the short term hydrostatic pressure (STHP) of at least one
sample per production lot shall be determined in accordance with ASTM D1599 at
standard laboratory temperature and the value should not be less than mean of
STHP for the representative product established in the qualification test. The test
report for qualification and quality control shall be certified by reputed certifying
agencies like LRS, DNV, BV, ABS, TUV, Vetco Tuboscope.

c) Test certificates shall be provided for use of GRE piping, fittings, O-rings, gaskets
and adhesives in potable water applications as per FDA /NSF / SHO or other Indian
regulatory Authorities

d) The fire water piping shall qualify endurance testing requirements as per Level 3
requirements of IMO Resolution A 753(18) or as latest version of ISO standard
14692-2 for glass reinforced plastics piping in Petroleum and Natural Gas
Industries.

e) The GRE pipe for dry portion of fire water system shall be designed such that line is
capable of withstanding initially fire up to maximum of 5 minutes by jet fire, flowed
by flowing water from deluge system by which time the line gets filled with water
due to actuation of deluge system. The heat flux of impinging flame shall be
decided based upon safety studies but the minimum heat flux considered shall be
between 300 and 400 kW/m2.

f) The GRE piping shall conform to the fire endurance tests for dry condition in
accordance with Appendix I of IMO resolution A. 753 (18), 1993

5.0 FABRICATION & INSTALLATION OF GRE PIPING

a) The piping and fittings shall be fabricated and installed as per UKOOA’s
“Specifications and Recommended Practice for the use of GRP Piping Offshore”,
March 1994.

b) All GRE piping shall be grounded through metallic parts in the system such as
valves, pumps, etc. and as per manufacturer’s recommendations

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c) All GRE components of fire water piping system shall be applied intumescent
coating for fire insulation / protection as per applicable standard/application. While
deciding type of intumescent, coating toxicity of the smoke shall also be
considered. Fire insulation material should be such a type that does not require the
use of reinforcing mesh.

6.0 CERTIFICATION REQUIREMENTS OF GRE PIPING

Offered product shall have valid class and type certificate from reputed certifying agencies
like LRS, DNV, BV, ABS.

7.0 LIST OF CODES AND STANDARDS FOR GRE COMPOSITE MATERIAL

PIPING

Standard Number Description

Standard Practice for Obtaining Hydrostatic or Pressure
ASTM D2992 Design Basis for “Fiberglass” (Glass-Fiber-Reinforced
Thermosetting-Resin) Pipe and Fittings.

Standard Specification for Filament-Wound “Fiberglass”

ASTM D2996
(Glass-Fiber-Reinforced Thermosetting Resin) Pipe

Standard Test Method for Longitudinal Tensile Properties

ASTM D2105 of “Fiberglass” (Glass Fiber Reinforced Thermosetting
Resin) Pipe and Tube

Standard Test Method for Cyclic Pressure Strength of

ASTM D2143
Reinforced, Thermosetting Plastic Pipe.

Standard Specification for Reinforced Epoxy Resin Gas

ASTM D2517
Pressure Pipe and Fittings.

Standard Specification for Centrifugally Cast “Fiberglass”

(Glass-Fiber-Reinforced Thermosetting-Resin) Pipe details
ASTM D2997
the specifications for machine made glass fiber reinforced
thermosetting resin pressure pipe.

Standard Practice for Determining Chemical Resistance to

ASTM C581
Thermosetting Resins.

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Standard Number Description

ASTM D570 Test Method for Water Absorption of Plastics.

Standard Test Method for Apparent Hoop Tensile

ASTM D2290 Strength of Plastic or Reinforced Plastic Pipe by Split Disk
Method.

Standard Test Method for Determination of External

ASTM D2412 Loading Characteristics of plastic pipe by parallel – plate
Loading sets forth methods.

Standard Test Method for External Pressure Resistance of

ASTM D2924 “Fiberglass” (Glass Fiber Reinforced Thermosetting Resin)
Pipe.

Standard Specification for “Fiberglass” (Glass Fiber

ASTM D5685-01
Reinforced Thermosetting Resin) Pressure Pipe Fittings.

ASTM D638 Standard Test Method for Tensile Properties of Plastics.

Standard Test Method for Time to Failure of Plastic Pipe

ASTM D1598
Under Constant Internal Pressure.

Standard Test Method for Resistance to short time

ASTM D1599
Hydraulic Pressure of Plastic Pipe, Tubing and Fittings.

Specification and Recommended Practice for the Use of

UKOOA
FRP Piping.

API Spec 15 LR Low pressure fiberglass line pipe.

API Spec 15 HR High pressure fiberglass line pipe.

Recommended Practice for Care and Use of Fiberglass

API RP 15 TL 4
Tubulars.

ASME B16.5 Pipes, Flanges and Flange Fittings.

ASME B31.3 Process Piping.

ASME BPVC Section X. Boiler & Pressure Vessel Code

ASTM D695 Test Method for Compressive Properties of Rigid Plastic.

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Standard Number Description

Test Method for Coefficient of Linear Thermal Expansion
ASTM D696
of Plastic.

AWWA C950 Standard for Fiberglass Pressure Pipe.

Specification for Glass reinforced plastic (GRP) pipes,

BS 5480
joints and fittings for use for water supply or sewerage.

Specification of reinforced plastic pipes, fittings and joints

BS 6464
for process plants.

Test for deflection temperature of plastics under flexural

ASTM D648
loads.

Classification for machine made reinforced thermosetting

ASTM D2310
resin pipe.

ASTM D1652 Test Method for epoxy content of epoxy resins.

Test Method for Tensile Properties of Glass Fiber Strands,

ASTM D2343
Yarn and Roving use in Reinforced plastics.

Apparent Inter Laminar Shear Strength of Parallel Fiber

ASTM D2344
Composites by Short Beam Method.

Standard Test Method for Viscosity of Epoxy Resin and

ASTM D2393
Related Components.

Standard of Test Method for Gel Time and Peak

ASTM D2471 Exothermic Temperature of Reacting Thermosetting
Resin.
Standard Test Method for Classifying Visual Defects in
ASTM D2563
Glass Reinforced Plastics Laminate Parts.

Standard Test Method for Indentation Hardness of Rigid

ASTM D2583
Plastics by mean of Barcol Impresser.

ASTM D2584 Test Method for Ignition Loss of Cured Reinforced Resins.

ASTM G53 Weathering QUV Weatherometer.

UKOOA Guidelines for Fiber Reinforced Use Offshore.

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Standard Number Description

US Coast Guard Guide on Fire test requirements for
USCG PFM 1-98
plastic pipe.

IMO A 753(18) Guidelines for application of plastic pipes on ships.

Petroleum & Natural Gas Industries – Glass Reinforced

ISO 14692 Part 1-4
Plastics Piping.

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