LAYING AND ASSOCIATED WORKS FOR HMEL CONNECTIVITY...

LAYING AND ASSOCIATEDWORKS FORHMEL CONNECTIVITY PIPELINEPROJECT, BHATINDA Project : P.013828Document No. : P.013828 D11031 001E - Tender No. 8000014912

GAIL (India) LimitedNoida | INDIA

PUBLIC

24 April 2019

TENDERTechnical-Piping, Vol.II of II, Rev.00

PIPING SPECIFICATION

6C1DOC. NO :

P.013828 D 11077 201SHEET 1 OF 6

ASME B 31.8 Carbon Steel - 20 to 65 Carbon Steel 72.00600#-RF LTCS - 45 to 65 LTCS 72.00

(BARE PIPE - TO BEPAINTED AT SITE)

LTCS (See Note 3)

CARBON STEEL Temperature(Deg.C)

Pressure bar (g)

° C bar (g)

CORROSION ALLOWANCE -29 102.04

CARBON STEEL 2.0 mm 0 102.04

2.0 mm 38 102.04

100% 93 93.08

PIPE SIZE RANGE 1/2"- 12"

00 23.04.2019 MS NC SKHREV DATE PREAPARED CHECKED APPROVED

LTCS

DESIGN CODE

MAXIMUM PIPELINE DESIGN CONDITIONS

3. MATERIAL FOR 1/2" TO 10" STATION PIPING SHALL BE ASTM A 333, GRADE 6 (LTCS). LTCS MATERIAL SHALL BE CHARPYIMPACT TESTED AT (-45 °C).

X-RAYS

BASIC MATERIAL

PRIMARY FLANGE RATING

Note :1. '6C1' INDICATES - 600# PIPING AND PIPELINE

AG : ACTUATING GAS

BASIC PIPING SPECIFICATION DATASTEMPERATURE °C

6 C1 - PMS for PIPELINE AND STATION Piping

Temperature & Pressure Rating

DESCRIPTIONIssued for RFP

2. ALL ABOVE GROUND (A/G) STATION PIPES SHALL BE BARE PIPES. THE PIPES SHALL BE PAINTED AT SITE, AS PER PROJECTSPECIFICATIONS FOR PAINTING OF ABOVE GROUND STATION PIPING.

Laying and Associated Works For HMEL ConnectivityPipeline Project

PRESSURE bar(g)

FLUIDS

1/2" to 10"

12"

NG : NATURAL GAS

Laying and Associated Works For HMEL Connectivity Pipeline Project


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REV. 00ITEM SHORT SIZE END RATING DIMENSION MATERIAL REMARKS

CODE FROM- CONNECTION AND/OR STANDARD

THRU SCH/THK

PIPES P 1/2" - 1 1/2" PE-ANSI B16-25 160 ANSI B 36-10 ASTM A333 GR 6 SEAMLESS (LTCS)

PIPES P 2" BE-ANSI B16-25 160 ANSI B 36-10 ASTM A333 GR 6 SEAMLESS (LTCS)

PIPES P 3" - 10" BE-ANSI B16-25 80 ANSI B 36-10 ASTM A333 GR 6 SEAMLESS (LTCS)

PIPES P 12'' BE-ANSI B16-25 7.1 mm Thk API 5L API5L X 70 12" - CLASS 1




PIPES P 12'' BE-ANSI B16-25 8.7 mm Thk API 5L API5L X 70 STATION PIPING.

PIPES P 12'' BE-ANSI B16-25 9.5 mm Thk API 5L API5L X 70 12" HOT INDUCTION BENDS AT STATIONS (CLASS 4 THICKNESS)

ELBOWS 90 LR E 1/2"- 1 1/2" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A 350 LF2, CL1 SMLS

ELBOWS 90 LR E 2"- 10" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6 SMLS

ELBOWS 90 LR E 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

ELBOWS 45 LR note 1 E45 1/2"- 1 1/2" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A 350 LF2, CL1 SMLS

ELBOWS 45 LR note 1 E45 2"- 10" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6 SMLS

ELBOWS 45 LR note 1 E45 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

REDUCERS CONC RC 1/2"- 1 1/2" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A 350 LF2, CL1 SMLS

REDUCERS CONC RC 2"- 10" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6 SMLS

REDUCERS CONC RC 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

REDUCERS ECC RE 1/2"- 1 1/2" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A 350 LF2, CL1 SMLS

REDUCERS ECC RE 2"- 10" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6 SMLS

REDUCERS ECC RE 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

TEES EQUAL T 1/2"- 1 1/2" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A 350 LF2, CL1 SMLS

TEES EQUAL T 2"- 10" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6 SMLS

TEES EQUAL T 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

TEES RED Note 13

(See Note 1) TR 3"- 10"

(Mainline Size)BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6

SMLSThe size inicated in this table refers to Mainline sizeof Tee Connection. For Branch Size, Please refer to

the Chart given in Sheet 6 of this Document.

TEES RED Note 13

(See Note 1)

12''(Mainline Size) BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

SMLSThe size inicated in this table refers to Mainline sizeof Tee Connection. For Branch Size, Please refer to

the Chart given in Sheet 6 of this Document.

BARRED TEE EQUAL(See Note 1)

T2 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70 SMLS

BARRED TEE RED(See Note 1)

TR2 12''(Mainline Size)

BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70The size inicated in this table refers to Mainline sizeof Tee Connection. For Branch Size, Please refer tothe Chart given in Sheet 6 of this Document.

WELDOLETS WEL 1 1/2"-10''(Mainline Size)

BW - ANSI B16-25 SEE PIPE & note 1 MSS-SP-97 ASTM A 350 LF2, CL1The size inicated in this table refers to Mainline size.For Branch Size of Weldolet, Please refer to the Chart

given in Sheet 6 of this Document

WELDOLETS WEL 12''(Mainline Size) BW - ANSI B16-25 SEE PIPE & note 1 MSS-SP-97 ASTM A 350 LF2, CL1

The size inicated in this table refers to Mainline size.For Branch Size of Weldolet, Please refer to the Chart

given in Sheet 6 of this DocumentCAPS C 1/2"- 10" BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 ASTM A420 WPL 6

CAPS C 12'' BW - ANSI B16-25 SEE PIPE & note 1 ANSI B16-9 API5L X70 or A860 WPHY 70

NIPPLES NBEP 1/2" - 1 1/2" BOTH ENDS PLAIN 160 ANSI B36-10 ASTM A333 GR 6 SEAMLESS-LG=100mm

NIPPLES NOET 1/2" - 1 1/2" ONE END THRD-MNPT 160 ANSI B36-10 ASTM A333 GR 6 SEAMLESS-LG=100mm

NIPPLES NBET 1/2" - 1 1/2" BOTH ENDS THRD-MNPT

160 ANSI B36-10 ASTM A333 GR 6 SEAMLESS-LG=100mm

FULL COUPLINGS CF 1/2" - 1 1/2" FNPT 3000# ANSI B16-11 ASTM A 350 LF2, CL1 THREADED

FULL COUPLINGS CF ANSI B1-20-2

CAPS C2 1/2" - 1 1/2" FNPT 3000# ANSI B16-11 ASTM A 350 LF2, CL1

THRD C2 ANSI B1-20-1

PLUGS PL 1/2" - 1 1/2" MNPT 3000# ANSI B16-11 ASTM A 350 LF2, CL1

THRD ANSI B1-20-1

Laying and Associated Works For HMEL Connectivity PipelineProject

6 C1 - PMS for Piping

NOTE 1 :WALL THICKNESS FOR TEES, ELBOWS, REDUCERS AND CAPS SHALL BE DETERMINED BY VENDOR AS PER THE REQUIREMENTS OF ASME B 16.9 § 2.3. MINIMUM THICKNESS OF TEESHALL ALSO MEET THE REQUIREMENTS OF ASME B 31.8, APPENDIX -F FOR BRANCH OPENING. FURTHER, MINIMUM THICKNESS OF TEES, ELBOWS, REDUCERS AND CAPS SHALLNOT BE LESS THAN THAT OF MATING PIPE. ALL WALL THICKNESS CALCULATIONS SHALL BE APPROVED BY OWNER. THE MATING PIPE DETAILS SHALL BE TAKEN AS MENTIONEDIN THE PIPE SECTION OF THIS PMS.



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REV. 00ITEM SHORT SIZE END RATING DIMENSION MATERIAL REMARKS


THRU SCHED.WN FLANGESnote 2

F 1/2"- 2" BW - ANSI B16-25 600# WNRF, SCH 160 ANSI B16-5 ASTM A350 LF2, CL1 Note 2

WN FLANGESnote 2

F 3"- 10" BW - ANSI B16-25 600# WNRF, SCH 80 ANSI B16-5 ASTM A350 LF2, CL1 Note 2

WN FLANGESnote 2

F 12'' BW - ANSI B16-25 600# WNRF, SEE PIPE ANSI B16-5 ASTM A694 F70 OR EQUIVALENT Note 2

ORIFICE FO 1" - 10" For 600 # WNRF ANSI B16-36 ASTM A350 LF2, CL1

ORIFICE FO 12'' For 600 # WNRF ANSI B16-36 ASTM A694 F70 OR EQUIVALENT

BLIND FB 1/2"- 10" For 600 # WNRF ANSI B16-5 ASTM A350 LF2, CL1

BLIND FB 12'' For 600 # WNRF ANSI B16-5 ASTM A694 F70 OR EQUIVALENT

SPECTACLE SB 1" - 10" For 600 # WNRF ANSI B16.48 ASTM A350 LF2, CL1

SPECTACLE SB 12'' For 600 # WNRF ANSI B16.48 ASTM A694 F70RESTRICTION

ORIFICERO 1" - 10" For 600 # WNRF ANSI B16-5 ASTM A240 GR 304

RESTRICTIONORIFICE

RO 12'' For 600 # WNRF ANSI B16-5 ASTM A694 F70

MONOLITHICINSULATIONJOINT

IJ 2"-10" BW - ANSI B16-25 600# MANUF STD. ASTM A350 LF2 CL1,or A420 WPL 6

Note 2

MONOLITHICINSULATIONJOINT

IJ 12'' BW - ANSI B16-25 600# MANUF STD. ASTM A694 F70 Note 2

STUD BOLTS B All Sizes For 600 # WNRFASME B 18.2.1 &

ASME B 18.2.2STUD BOLTS: ASTM A320 GR. L7,HEXAGONAL NUTS : ASTM A194

GR 4GASKETS

SPIRALWOUND

G All Sizes For 600 # WNRF ASME B 16.20WINDING AISI 304, FILLING PUREGRAPHITE. CENTERING RING CS 4.5 mm THK

NOTE 2 :BORE OF FLANGE SHALL MATCH INSIDE DIA OF MATING PIPE. THE MATING PIPE DETAILS SHALL BE TAKEN AS MENTIONED IN THE PIPE SECTION OF THIS PMS.

Laying and Associated Works For HMEL Connectivity PipelineProject




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ITEM SHORT SIZE END RATING DIMENSION MATERIAL REMARKS


THRU SCHED.

BALL VALVES(See Note 3) VBA 1/2" - 1 1/2" FLGD RF:ANSI B16-5 600# ANSI B16-10

BODY : ASTM A350 LF2, CL1 /ASTM A 352 Gr. LCBBALL : ASTM A 182 Gr. F316 ORASTM A 351 GR. CF8M OR(ASTM A350 LF2, CL1 / ASTM A352 Gr. LCC) + ENP

FULL BOREFIRE SAFEWRENCH OPERATED.

BALL VALVES(See Note 3) VBA 2" - 4" FLGD RF:ANSI B16-5

or BW: ANSI B16-25 600# ANSI B16-10


DOUBLE BLOCK AND BLEEDFULL BOREFIRE SAFEWRENCH OPERATED

BALL VALVES(See Note 3) VBA 6"- 12'' FLGD RF:ANSI B16-5

or BW: ANSI B16-25 600# ANSI B16-10


DOUBLE BLOCK AND BLEEDFULL BOREFIRE SAFEGEAR OPERATED :MANUAL / ACTUATED - ASINDICATED IN DATA SHEET

GLOBE VALVES

VGL 1/2"-1 1/2" FLGD RF:ANSI B16-5 600# ANSI B16-10

BODY : ASTM A350 LF2, CL1 /ASTM A 352 Gr. LCCDISC / RING : (ASTM A350 LF2,CL1 / ASTM A 352 Gr. LCC) + 13%CR. STEEL FACINGSTEM : 13% CR. STEEL (NOCASTING)

HANDWHEEL FIRE SAFE

VGL 2" - 4" FLGD RF:ANSI B16-5 600# ANSI B16-10


HANDWHEEL FIRE SAFE

VGL 6" - 12" FLGD RF:ANSI B16-5 600# ANSI B16-10


GEAR OPERATED FIRE SAFE

SWING CHECK

VCH 2"- 12'' FLGD RF:ANSI B16-5 600# ANSI B16-10

BODY : ASTM A350 LF2, CL1 /ASTM A 352 Gr. LCCHINGE PIN : 13% CR. STEEL (NOCASTING)DISC / RING : ASTM A350 LF2,CL1 / ASTM A 352 Gr. LCC)+ 13% CR. STEEL FACING

HORIZONTAL INSTALLATIONVERTICAL INSTALLATION FLOWUPWARDS

NOTE 3 :PUP PIECES SHALL BE PROVIDED FOR BUTT WELDED VALVES AS PER THE DATASHEET. MINIMUM THICKNESS OF PUP PIPECE SHALL BE DETERMINEDBY VENDOR AS PER THE REQUIREMENTS OF ASME B 31.8, FIG I-5 FOR WELDING TO VALVE DESIGNED AS PER ASME B 16.34. THE THICKNESSCALCULATIONS SHALL BE APPROVED BY CLIENT. THE PIPE END OF THE PUP PIECE SHALL MATCH THE THE MATING PIPE.THE MATING PIPE DETAILSSHALL BE TAKEN AS MENTIONED IN THE PIPE SECTION OF THIS PMS.

Laying and Associated Works For HMEL ConnectivityPipeline Project




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P.013828 D 11077 201SHEET 5 OF 6

REV. 00

SMALL SIZE

1/2"3/4" 1" 1.1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20"1/2"3/4" X1" X X

L 1.1/2" X X XA 2" X X XR 3" X XG 4" X X XE 6" X X

8" X XS 10" X X XI 12" X X Xz 14" X X X XE 16" X X X X

18" X X X X20" X X X X24" X X X

LEGENDX : CONCENTRIC AND ECCENTRIC REDUCERS- BW

REDUCERS CHART

Laying and Associated Works For HMELConnectivity Pipeline Project



BRANCH SIZE

1/2" 3/4" 1" 1.1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24"1/2" T3/4" TR T1" TR TR T

H 1.1/2" W TR TR TE 2" W W TR TR TA 3" W W W TR TR TD 4" W W W W TR TR TE 6" W W W W W TR TR TR 8" W W W W W BW* TR TR T

10" W W W W W BW* BW* TR TR TS 12" W W W W W BW* BW* BW* TR TR TI 14" W W W W W BW* BW* BW* BW* TR TR TZ 16" W W W W W BW* BW* BW* BW* BW* TR TR TE 18" W W W W W BW* BW* BW* BW* BW* BW* TR TR T

20" W W W W W BW* BW* BW* BW* BW* BW* BW* TR TR T24" W W W W W BW* BW* BW* BW* BW* BW* BW* BW* TR TR T

LEGENDT : TEE EQUAL-BWTR : REDUCING TEE-BW (FLOW TEE WHEREVER INDICATED SHALL BE PROVIDED)W : WELDOLET- BWBW : BRANCH WELD-CHECK IF REINFORCING PLATE IS NECESSARY ACCORDING ANSI B 31.8 (See Note)

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P.013828 D 11077 201SHEET 6 OF 6

REV. 00

BRANCH CHART

*NOTE : IN PLACE OF BRANCH -WELD, EXTRUDED TEE, CONFORMING TO ASME B 16.9 SPECIFICATION,MAY BE USED, SUBJECT TO AVAILABILITY

Laying and Associated Works For HMEL Connectivity Pipeline Project6 C1 - PMS for Piping



PTS - SPIRAL WOUNDMETALLIC GASKETS

P.013828D 11077

204

Page 1 of 5

VENDOR LOGO

IRCA LOGO

HMEL CONNECTIVITY PIPELINE PROJECT, BHATINDA

TRACTEBEL ENGINEERING PVT. LTD.

PTS - SPIRAL WOUND METALLIC GASKETS

00 23.04.2019 Issued for RFP MK MS SKH

Rev. Date Subject of Revision Prepared By Checked By Approved By


P.013828D 11077

204

Rev. 00 HMEL Connectivity Pipeline Project. Page 2 of 5

TABLE OF CONTENTS

1. SCOPE............................................................................................................................ 3

2. REFERENCE DOCUMENTS.............................................................................................. 3

3. DESCRIPTION OF THE MATERIALS ............................................................................... 3

4. QUALITY CONTROL ....................................................................................................... 4

5. MANUFACTURER's DOSSIER / FINAL DOCUMENTATION ............................................. 4

6. PREPARATION FOR SHIPMENT..................................................................................... 5

∑ ∑ ∑


P.013828D 11077

204


1. SCOPE

This specification completes the description shown on individual piping material classes and coversthe technical requirements for the fabrication, inspection, and shipment of spiral-wound gaskets, andring joints used for pipeline and piping flanges.

2. REFERENCE DOCUMENTS

ASME B 31.8 : Gas Transmission and Distribution Piping System.

ASME B 16.20 : Metallic Gaskets for Pipe Flanges - Ring-Joints,Spiral-Wound, and Jacketed.

ASME B 16.5 : Steel Pipe Flanges and Flanged Fittings.

ASME B 16.47 : Large Diameter Steel Flanges (NPS 26 throughNPS 60).

ASTM F 36 : Standard Specification for Test Method forCompressibility and Recovery of GasketMaterials.

EN 10204 : Metallic products - Type of inspection documents.

3. DESCRIPTION OF THE MATERIALS

3.1. GENERAL

All gaskets shall conform to the codes/standards and specifications given in the requisition. Vendorshall strictly comply with Purchase Requisition stipulations and no deviations shall be permitted.

Process of manufacture, dimensions and tolerances not specified in requisition shall be in accordancewith the requirements of the manufacturer’s standards.

Asbestos containing gaskets are prohibited.

Materials, dimensions, tolerances and markings shall comply with ASME B 16.20.

3.2. Spiral Wound Gaskets

The gaskets shall be in accordance with the standard ASME B16.20and their spiral-wound portion shallbe made from type 316 stainless steel (or higher grade, depending on the relevant piping materialspecification) strip.

Filler material for spiral wound gaskets shall not have any colour or dye.

GRAPHITE based fillers shall incorporate an adequate corrosion inhibitor in order to prevent frompossible galvanic corrosion.

All spiral wound gaskets shall be supplied with Outer ring& Inner ring irrespective of their class, rating& Size unless otherwise specified.

The gaskets shall have an external centering ring and an inner ring.

Inner compression ring material shall be same as winding material. The outer rings are made of eithercoated carbon steel or of stainless steel.

Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 up to 24” (except22”size) and to ASME B16.47 (Series A) for 22” and above 24” unless specifically mentionedotherwise.

3.3. Metal Ring Joint

Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwisespecified.


P.013828D 11077

204


Table 3-1: RTJ Hardness

Ring Gasket Material Maximum Max. Hardness (BHN)

Soft Iron 90

Carbon steel 120

5Cr½ Mo 130

18/8 Stainless Steel 135

3.4. Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

Ring joints may be either oval or octagonal. The dimensions of ring joints shall be in accordance withthe standard ASME B16.20, and shall be specified to match with the relevant flanges standard.

4. QUALITY CONTROL

The inspection and tests necessary to confirm that the products meet the requirements of the standards,specifications, and requisitions, shall be carried out in the MANUFACTURER's plant by personnel ofthe plant. These specially qualified personnel shall be independent of the production department of theplant.

Products shall be guaranteed by an inspection certificate (conformity, material, etc.) that mustaccompany the supply. If the Manufacturer does not have the necessary means of examination, thesetests may be carried out by an Inspection agency and at a place approved by the Company.

All inspection and testing shall be carried out as per standard & the QAP provided elsewhere in the bid.

All items shall be inspected and approved by Approved Third party inspector or any other agencyauthorized by owner.

4.1. Testing

Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified in therequisition and the QAP.

Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of test reportson samples.

For Spiral wound material following shall be furnished:

Manufacturer's test certificate for filler material and spiral material as per the relevant materialspecifications.

Manufacturer's test certificate for raw materials and tests for compressibility/ seal-ability & recovery asper the relevant material specifications.

PMI shall be performed as per standard and QAP.

5. MANUFACTURER's DOSSIER / FINAL DOCUMENTATION

5.1. Certificate of conformity

The Manufacturer shall submit certificates of conformity to the standards specified by the requisitionsfor spiral-wound gaskets, and metal ring joints.

5.2. Material certificates

The Manufacturer shall submit material certificates in accordance with the requirements of thereference codes, standards and QAP.


P.013828D 11077

204


6. PREPARATION FOR SHIPMENT

6.1. Marking

1.1.1. Spiral-wound gaskets

In addition to the marking required by the standard ASME B16.20, the following information shall bemarked by cold stamping on the centering ring of each spiral-wound gasket:

a. The MANUFACTURER's name and trademarkb. The diameterc. The rating

1.1.2. Metal ring joints

In addition to the marking required by the standard ASME B16.20, the outside surface of each ringshall include the following information which shall be marked by cold stamping:

a. The MANUFACTURER's name and trademarkb. The diameterc. The ratingd. The ring number, followed by the identifying reference of the material.

6.2. Color Coding

Spiral-wound gaskets shall be marked with a color code that identifies the windings and filler materialsas per ASME B 16.20.

6.3. Protection

Ring joint gaskets other than those made of stainless steel shall be covered by grease impregnatedprotecting strips.

Small diameter gaskets shall be grouped in cardboard boxes or plastic pouches and large diametergaskets in rigid packing cases.

6.4. Packing

The gaskets must be packed in sea-packing, which must be tight and meet the requirements of allstages of transport (rail, road, air, etc.).

The gaskets of different types and sizes shall be place in separate shipping containers.

Each container shall clearly mark with size, rating, material specification and item code.

Abbreviations:AARH : Average Arithmetic Root HeightBHN : Brinnel Hardness NumberCS : Carbon SteelMR : Material RequisitionPMI : Positive Material IdentificationRTJ : Ring Type Joint

QAP : Quality Assurance Program

∑ ∑ ∑

PTS - STEEL FASTNERSP.013828D 11077

205

Page 1 of 5

VENDOR LOGO

IRCA LOGO



PARTICULAR TECHNICAL SPECIFICATION -

P

RERT

PTS – STEEL FASTNERS




205

Rev. 00 Laying and Associated Works For HMEL Connectivity Pipeline Project Page 2 of 5

TABLE OF CONTENTS

1. GENERAL.................................................................................................................................... 3

2. REFERENCE DOCUMENTS .......................................................................................................... 3

3. SPECIFIC REQUIREMNT ............................................................................................................ 4

4. TESTING..................................................................................................................................... 5

∑ ∑ ∑


205


1. GENERAL

The process of manufacture, heat treatment, chemical & mechanical requirements and marking for all stud

bolts, m/c bolts, Jack screws & nuts shall be in accordance with the codes/standards and specifications

given in the requisition. The applicable identification symbol in accordance with the material specification

shall be stamped on each bolt and nut. Vendor shall strictly comply with this specification & QAP and no

deviations shall be permitted.

2. REFERENCE DOCUMENTS

Reference has been made in this specification to the latest edition (edition enforce at the time of issue

of enquiry unless specified otherwise) of the following Codes, Standards and Specification.

ASME B31.8 : Gas Transmission and Distribution Piping Systems.

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

ASMEB16.5 : Pipe Flanges and Flanged Fittings NPS ½" Through NPS 24 Metric/Inch Standard

ASME B18.2.1 : Square and Hexagonal Bolts and Screws (Inch Series)

ASME B18.2.2 : Square and Hexagonal Nuts (Inch Series)

ASTM A193 : Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High

Temperature or High Pressure Service and Other Special Purpose Applications.

ASTM A194 : Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High

Temperature or High Pressure Service, or Both.

ASTM A307 : Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile

Strength.

ASTM A320 : Standard Specification for Alloy-Steel and SS Bolting Materials for Low-

Temperature service.

ASME 18.2.1 : Square and Hex Bolts and Screws (Inch Series)

ASME 18.2.2 : Square and Hex Nuts (Inch Series)


205


ASME B16.5 : Pipe Flanges and Flanged Fittings up to 24”

ASME B16.47 : Large Diameter Steel Flanges (NPS 26 through NPS 60)

3. SPECIFIC REQUIREMNT

3.1. All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jackscrews and ANSI B18.2.2 for nuts

and material.

3.2. Material of Stud Bolts shall be ASTM 320 Gr. L7

3.3. Material of Nuts shall be ASTM 194 Gr. 4 /Gr. 7

3.4. Threads shall be unified (UNC for 1" dia. and 8UN for > 1" dia.) as per ANSI B1.1 with class 2A fit for

studs, M/c bolts and jackscrews and class 2B fit for nuts.

3.5. Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance shall be in

accordance with the requirement of table D2 of Annexure-D of ANSI B 16.5.

3.6. The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the hot

forged process and stamped as per respective material specification.

3.7. Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be rounded.

3.8. Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in separate containers marked

with size and material specifications.

3.9. All items shall be inspected and approved (stage wise) by TPIA.

3.10. The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.

3.11. All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed condition unless

specified otherwise in the material specification.

3.12. Any additional requirements specified in the requisition shall be fully complied with.

3.13. 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 A153’. As an alternative, electro¬-galvanizing as per IS 1573,

‘Service Grade Number 2’ is also acceptable.

3.14. All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts irrespective of whatever

has been specified elsewhere in the MR.


205


3.15. Each stud bolt shall be supplied with matching two nuts and two washers

3.16. Bolts/Nuts shall be protected by non-corrosive oil or grease before dispatch to prevent rusting.

4. TESTING

4.1. Test reports shall be supplied for all mandatory tests as per the relevant material specifications.

4.2. Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and Mechanical

Requirement)

4.3. PMI shall be performed as per the scope and procedures defined in the Specification for PMI at

Vendor’s Works.

4.4. Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453 bolting material

irrespective of the temperature.

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VENDOR LOGO

IRCA LOGO



PTS - INSULATING GASKET




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TABLE OF CONTENTS

1.0 INTRODUCTION .................................................................................................................3

2.0 DEFINITIONS......................................................................................................................3

3.0 TECHNICAL SPECIFICATION ............................................................................................3

4.0 INSPECTION AND TESTING..............................................................................................4

5.0 TEST CERTIFICATES ..........................................................................................................5

6.0 MARKING AND SHIPMENT................................................................................................5

7.0 DOCUMENTATION ..............................................................................................................5


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1.0 INTRODUCTION

This Document (PTS - Particular Technical Specification for – Insulating Gaskets) lists the Specification forManufacturing/Supplier of Insulating Gasket, for the project..

This present document covers the technical specification for the procurement of Insulating Gaskets used inhigh pressure natural gas transmission systems. It describes the general requirements, controls, tests,QA/QC examination and final acceptance criteria which need to be fulfilled.

2.0 DEFINITIONS

Client / Owner Shall mean GAIL ( I) Limited

Manufacturer Means the Manufacturer of the Insulating Gasket.

EPC Contractor / Contractor The party which carries out all or part of Engineering,Procurement, Construction, Pre-commissioning & Commissioningof the project. It shall mean EPC Contractor in the present context.

Third Party InspectionAgency (TPIA)

Means the Inspection Agency to be appointed by the EPCcontractor

Consultant / OwnerRepresentative

Shall means TRACTEBEL Engineering Pvt. Limited / The entityof the purchaser or the company nominated by the purchaser todesign the natural gas transport or distribution system and tospecify the equipment

PTS Means the present <<Particular Technical Specification P.013828M 11077 206>>and its entire appendix, if any.

3.0 TECHNICAL SPECIFICATION

3.1 The material of insulating gasket kit shall be as follows:

i. Insulating Gaskets: It shall be machined glass reinforced epoxy (GRE) resin (G 10 or G11) with O-ring or spring energised seal made from rubber/PTFE.

ii. Insulating Washer: - Material shall be GRE.

iii. Insulating sleeve: - Material shall be GRE. Insulating length shall be two flange thicknessincluding raised face, plus gasket, plus two insulating washers, plus one steel washer.

iv. Steel machine cut washer: - It shall be zinc plated steel.

3.2 One Insulating Gasket kit shall consist of one no. central insulating gasket, one no. insulating sleeve perbolt, two nos. insulating washer per bolt and two nos. metallic washer per bolt.

3.3 Manufacturer shall guarantee that Insulating Gasket shall with stand test pressure equal to 1.5 times designpressure of Pipeline.

3.4 The dimensions of the gaskets shall be suitable for WNRF flange as per ASME B 16.5

3.5 The Insulating gaskets is required for 600# ratings.

3.6 The minimum thickness of insulating gasket shall be 3 mm.

3.7 Insulating gaskets shall have bolt holes punched out.


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3.8 Asbestos shall not be used.

3.9 The insulating gaskets shall match flanges ( Weld neck raised face & Blind face ) to ASME 16.5

3.10 Packing size of Insulating Gaskets Kit to be mentioned to ensure uniformity in delivery conditions of thematerial being procured. Bidder shall submit the packaging details during offer and also complied with atthe time of delivery.

3.11 Following electrical properties:

· Dielectric Strength (min.) = 550 VPM

· Electrical Resistance = 25 Mega Ohm

(When tested with 500-1000V DC megger).

3.12 Each kit shall be clearly marked with the size, rating, material specification etc.

3.13 Inspection shall be carried out as per Technical Specification.

Owner Representative or Third Party Inspection Agency appointed by Supplier shall carry out stage wiseinspection during manufacturing / final inspection.

Vendor shall furnish all the material test certificates, proof of approval / licence from specified authority asper specified standard, if relevant, internal test / inspection reports as per Owner Tech. Spec. & specifiedcode for 100% material, at the time of final inspection of each supply lot of material.

4.0 INSPECTION AND TESTING

The manufacturer shall perform all inspections and tests as per the requirements of this specification and theapplicable codes at his works prior to shipment. Such inspections and tests shall be, but not be limited to thefollowing :

4.1 All the insulating gasket assemblies shall be visually inspected.

4.2 Insulating flange assembly shall be hydrostatically tested to a pressure equal to 1.5 times design Pressure infollowing manner;

· 5 minutes at a hydrotest pressure.

· Reduce to Zero.

· Repeat the above procedure twice

4.3 Insulating flange assembly shall be tested with air at 5 kg/cm2 for 10 minutes. The tightness shall bechecked by immersion or with a frothing agent. No leakage shallbe accepted.

4.4 Dimensional checks shall be carried out as per Approved Drawings.

4.5 Chemical composition and mechanical properties shall be checked as per relevant material standards andthis specification, for each heat of material used.

4.6 Each insulating gasket shall be tested for dielectric integrity at 5000 V A.C., 50 Hz for one minute and theleakage current before and after shall be equal. Testing time, voltage and leakage shall be recorded andcertified. The test shall be carried out in dry conditions.

4.7 The insulation resistance of each insulating gasket assembly shall be at least 25 mega ohms when checkedwith 500V - 1000V D.C. This test shall be carried out in dry conditions.

4.8 Each Insulating Gasket Assembly shall be Dielectric Tested before and after hydrostatic Test.

4.9 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated above atManufacturer’s Works prior to shipment. Manufacturer shall give reasonable notice of time and shall


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provide, without charge, reasonable access and facilities required for inspection by the Inspector.Inspections and tests performed/witnessed by the Inspector shall in no way relieve the Manufacturer of hisobligation to perform the required inspection and tests.

For any control, test or examination required under the supervision of TPIA/Owner/Owner’s representative,latter shall be informed in writing one (1) week in advance by vendor about inspection date and place alongwith production schedule.

Even after third party inspection, Owner reserves the right to select a sample of pipes randomly from eachmanufacturing batch & have these independently tested. Should the results of these tests fall outside thelimits specified in Owner technical specification, then Owner reserves the right to reject all productionsupplied from the batch.

5.0 TEST CERTIFICATES

Manufacturer shall submit following certificates to EPC contractor/owner/Owner’s representative:

a) Test certificates relevant to the chemical analysis and mechanical properties of the materials used forconstruction as per this specification and relevant standards.

b) Test reports as per QAP

c) Recorded and Certified Voltage and leakage

6.0 MARKING AND SHIPMENT

6.1 Marking

In addition to the marking required by the applicable standard, the following information shall be markedby cold stamping on the centering ring of each insulating gasket:

a. The MANUFACTURER's name and trademarkb. The diameterc. The rating

6.2 Packing

The gaskets must be packed in sea-packing, which must be tight and meet the requirements of all stages oftransport (rail, road, air, etc.).

7.0 DOCUMENTATION

Within two weeks of placement of order, the manufacturer shall submit two copies of the drawings,documents and specifications for approval.

Once the approval has been given by Owner/Owner’s Representative. Any change in design, material methodof manufacture shall be notified to Owner/Owner’s Representative whose approval in writing of all changesshall be obtained before the manufacturing.

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VENDOR LOGO

IRCA LOGO

HMEL CONNECTIVITY PIPELINE PROJECT,BHATINDA


PTS - PAINTING

00 23.04.2019 Issued for RFP MK MS AR


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TABLE OF CONTENTS

1.0 INTRODUCTION ................................................................................................................... 1

2.0 DEFINITIONS ....................................................................................................................... 1

3.0 COLOUR CODE SYSTEM........................................................................................................ 1

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1.0 INTRODUCTION

This Document (PTS - Particular Technical Specification for Painting) lists the Specification for the project.

This present document covers the technical specification for the procurement of Painting used in highpressure natural gas transmission systems. It describes the general requirements, controls, tests, QA/QCexamination and final acceptance criteria which need to be fulfilled.

In case of any conflict of Specification, PTS will supersede General Technical specification (GTS) andData sheet will supersede PTS.

2.0 DEFINITIONS

Client / Owner Shall mean GAIL ( I) Limited

Contractor The party which carries out all or part of Engineering,Procurement, Construction, Pre-commissioning & Commissioningof the project. It shall mean Pipe laying contractor in the presentcontext.


Means the Inspection Agency to be appointed by the Pipe layingcontractor



PTS Means the present <<Particular Technical Specification P.013828M 11077 207>>and its entire appendix, if any.

3.0 COLOUR CODE SYSTEM

The colour codes for final layer of Station Pipe Work & Metering Shed shall be as under:

S. No. DESCRIPTION FINAL LAYERCOLOUR SHADE

RAL CODE

1 Pipe Work Yellow RAL 1004

2 Piping Support Grey RAL 7043

3 Hand Rail Grey RAL 7043

4 Gas O/L Actuator Blue RAL 5015

5 Valve Handle/Wheel Black RAL 9005

6 All Valves Grey RAL 7038

7 IJ Grey RAL 7038


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8 Filter Grey RAL 7038

9 Pig launcher & Receiver Grey RAL 7038

10 Bolts & Nuts Grey RAL 7038

11 Grating Hot Galvanized

12 Metering Station Shed

12.1 Steel Frame Beige RAL 1018

12.2 Roof / Vertical Shed Grey RAL 7030

12.3 Control Panel Grey RAL 7032

The recommended painting system should be of Category C5 – I Very high (Industrial) as specified in the Standard ISO

12944 Part 1 to 8. The proposed Painting system shall conform to Table A5 of ISO 12944 – 5 Standard.


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PTS - FIELD JOINTCOATING

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Page 1 of 14

VENDOR LOGO

IRCA LOGO



PTS- FIELD JOING COATING




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TABLE OF CONTENTS

1.0 SCOPE...............................................................................................................................3

2.0 REFERENCE DOCUMENTS..............................................................................................3

3.0 MATERIALS AND EQUIPMENT ........................................................................................4

4.0 APPLICATION PROCEDURE............................................................................................7

5.0 INSPECTION AND TESTING...........................................................................................10

6.0 REPAIRS..........................................................................................................................11

7.0 DOCUMENTATION..........................................................................................................12


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1.0 SCOPE

1.1 This specification establishes the minimum requirements of materials, equipment and installation of fieldjoint anti-corrosion coating of buried onshore pipelines (for design temperature up to 65°C factory coatedwith either three layer polyethylene by heat shrink wraparound sleeves conforming to DIN EN 12068 —"Cathodic Protection — External Organic Coatings for the Corrosion Protection of Buried or ImmersedSteel Pipelines used in Conjunction with Cathodic Protection — Tapes and Shrinkable Materials" and therequirements of this specification. Unless modified/replaced by this specification, all requirements ofDIN EN 12068 shall remain fully applicable and complied with.

This specification shall be read in conjunction with the conditions of all specifications and documentsincluded in the Contract between Company and Contractor. Unless specified otherwise, all sections ofthis specification shall apply to all specifications referred in this specification.

2.0 REFERENCE DOCUMENTS

Reference has also been made to the latest edition (edition enforce at the time of issue ofenquiry) of the following standards, codes and specifications:

a) ASTM D-149 : Standard Test Methods of Dielectric Breakdown voltage andDielectric strength of solid electrical insulating materials atcommercial frequencies.

b) ASTM D-257 : Standard Test Methods for D-C Resistance or conductance ofinsulating materials

c) ASTM D-570 : Standard Method of Test for Water Absorption of Plastics.

d) ISO 8502- 3 : Preparation of Steel Substrates before Application of Paints andRelated Products —Part 3 - Assessment of Dust on SteelSurfaces Prepared for Painting (Pressure Sensitive TapeMethod).

e) ISO8503—1 : Part 1: Specification and definitions for ISO surface profilecomparator for the assessment of abrasive blast cleanedsurfaces.

f) ISO8503—4 : Part 4: Methods for calibration of ISO surface profilecomparator and for the determination of surface profile — Stylusinstrument procedure.

g) SIS-055900 : Pictorial Surface Preparation Standard for Painting SteelSurfaces.

h) SSPC-SP I : Steel Structure Painting Council.

i) DIN EN 12068 : Cathodic Protection — External Organic Coatings for theCorrosion Protection of Buried or Immersed Steel Pipelines


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used in Conjunction with Cathodic Protection — Tapes andShrinkable Materials.

In case of conflict between the requirements of this specification and that of above referreddocuments, the requirements of this specification shall govern.

The CONTRACTOR shall be familiar with the requirements of these documents and shallmake them readily available at the site to all personnel concerned with carrying out the worksspecified in this specification.

3.0 MATERIALS AND EQUIPMENT

3.1 Field joint anti-corrosion coating material shall be heat shrinkable wraparound sleeve for amaximum operating temperature of (+) 60°C (T max) and shall conform to designation EN12068 - C HT 60 UV. In addition, the field joint anti-corrosion coating shall comply therequirements specified in para 3.2 of this specification.

3.1.1 HEAT SHRINKABLE WRAP AROUND SLEEVES:

Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized,ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shearstrength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of asolvent free epoxy primer applied to the pipe surface prior to sleeve application. The backingshall be provided with suitable means (thereto-chrome paint, dimple, or other means) to indicatethe desired heat during shrinking in field is attained. The sleeve shall be supplied in pre-cutsizes to suit the pipe diameter and the requirements of overlap.

The total thickness of heat shrinkable wraparound sleeve in the as applied condition shall be asfollows:

Pipe Size(Specified Outside Diameter)

Thickness (mm)

On Pipe Body(Min)

On Weld Bead(Min.)

Up to 18” (457mm) 2.2 1.8

20” (508 mm) to 30” (762mm) 2.5 2.0

32” (813 mm) & above 3.0 2.5

The heat shrink wraparound sleeve shall have the required adhesive properties when applied onvarious commercial pipe-coating materials. The pre-heat and application temperatures required for


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the application of the shrink sleeve shall not cause loss of functional properties of the pipe coating.

The Contractor shall propose the manufacturer's details, heat shrinkable sleeve details/ propertiesand the specific grade of field joint coating system meeting the requirements of this specification.Contractor shall propose only those coating systems that have been previously used for pipelines ofsame or higher size than the size indicated in tender, for a length of 50 km and above in a singleproject for similar operating conditions.

3.2 Functional Requirements of Field Joint Coating

3.2.1 Properties of the PE backing shall be as follows:

Sl.No Properties Unit Requirement Test method

a. Tensile Strength @ +25°C N/mm2 ≥ 12 DIN EN 12068

b. Ultimate Elongation@ +25°C % ≥250 DIN EN 12068

c. Dielectric withstand with1000Volts/sec

KV ≥30 ASTM D 149

d. Water absorption,@+25°C for 24 hours

% ≥0.05 ASTM D 570

e. Volume Resistivity@ +25°C

Ohm-cm ≥1015 ASTM D 257

f. Shore D Hardness Shore D ≥55 ASTM D 2240

3.2.2 FUNCTIONAL PROPERTIES OF JOINT COATING SYSTEM (AS APPLIED)

As applied field joint coating system shall comply the requirements of DIN EN 12068, Table1 and 2 corresponding to designation DIN EN 12068 - C HT 60 UV, except as modifiedbelow:

Cathodic Disbondment Resistance at T. i.e 60°C shall be 20 mm when tested as per AnnexureK of DIN EN 12068. Test shall be carried out at (+) 60°C.

Peel Strength shall be as follows:

Peel Strength UnitRequirement forMech. Resistance

Class C (minimum)

Test methodas per

DIN EN 12068

Inner to Inner (+)Outer to Inner

@ 23°C N/mm 1.5Annexure B

@Tmax N/mm 0.3


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Outer to outer@ 23°C N/mm 1.5

@Tmax N/mm 0.3

To Pipe Surface@ 23°C N/mm 3.5

Annexure C@Tmax N/mm 1.5

To Factory Coating@ 23°C N/mm 3.5

@Tmax N/mm 1.5

NotesTmax shall be (+)60°C

Contractor shall obtain prior approval from Company regarding the Manufacturer of the joint coatingmaterial and the specific grade of the joint coating system. Complete technical details along with testcertificates complying with the requirements of clause 3.2.1 and 3 2 2 shall be submitted to Companyfor this purpose. The Contractor shall furnish test certificates from an independent DINrecognized/approved laboratory for all the properties required for the specified EN designation of fieldjoint coating and the requirements of this specification.

3.3 The material shall not be older than their period of validity at the time of application byContractor. Deteriorated/decomposed material shall be disposed off and replaced byContractor at his own expense.

Contractor shall ensure that the coating materials supplied by him are properly packed andclearly marked with the following:

- Manufacturer's name- Material qualification- Batch number- Date of manufacturing and date of expiry

3.4 Contractor shall ensure that the Manufacturer has carried out all quality control tests on eachbatch and manufacturer shall provide test certificates to certify that the supplied materials meetthe manufacturer's specifications as indicated in the purchase order and as approved byCOMPANY. Certificates and data sheets certifying the qualities of the coating materials shallbe submitted by Contractor to Company prior to application. Company reserves the right tohave the materials tested by an independent laboratory.

3.5 Materials shall be stored in sheltered storage in the manufacturer's original packing and awayfrom direct sunlight and in accordance with manufacturer's instructions.

3.6 Contractor shall provide and maintain mobile facilities which contain all necessary equipmentand its spares for cleaning, coating, repairs, inspection and tests.

3.7 Contractor shall furnish sufficient number of the following equipment and the required sparesas a minimum for inspection and test purposes for each crew:

a) Fully automatic full circle adjustable holiday detector with a visible and audible signalsystem for inspection of coatings

b) Thickness gauge for measuring thickness.


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c) Contact type temperature recording thermometer (Digital Pyrometer with flat probe typecontact)

d) Roughness profile measuring (Stylus) instrument

4.0 APPLICATION PROCEDURE

4.1 General

4.1.1 The application procedure shall be in accordance with manufacturer's instructions and theminimum requirements specified below whichever are the most stringent and shall bedemonstrated to and approved by the Company. Manufacturer's expert shall supervise theapplication and shall be available at site upon request during qualification of applicationprocedure and during construction at Contractor's cost.

4.1.2 Operators for coating application shall be given necessary instructions and training before startof work, by the Contractor. To verify and qualify the application procedures, all coatingapplied during the qualification test, shall be removed for destructive testing as detailedsubsequently in this specification. Contractor shall only utilize those operators who have beenapproved/pre-qualified by the field joint coating manufacturer.

4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked withsuitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose.Solvent cleaning procedure according to SSPC-SP1 shall be followed.

4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandableblasting equipment. With the first equipment type, steel or chilled shot and iron grit shall beused and Garnet material with the second one (in case the authority having jurisdiction have noobjection, the contractor may adopt sand blasting instead of garnet material). During blastcleaning the pipe surface temperature shall be simultaneously more than 5 °C and more than3°C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than85 %. Prior to surface cleaning the surfaces shall be completely dry. The surface shall becleaned to a grade Sa 21/2 in accordance with Swedish Standard SIS-055900 with a roughnessprofile of 50 — 70 microns. Surface roughness profile shall be measured using an approvedprofile comparator in accordance with ISO 8503-1 and shall be calibrated prior to the start ofthe work in accordance with ISO 8503-3 or ISO 8503-4. The blast cleanliness shall be checkedon every joint and the roughness profile shall be checked 1 every 10 joints.

Dust, girt or foreign matter shall be removed from the cleaned surface by an industrial vacuumcleaner. The dust contamination allowed shall be of a rating max 2 as per ISO 8502 -3. Thefrequency of checking for dust contamination shall be 1 every 10 joints.

Blast cleaned field joint shall be coated within 2 — 4 hours according to the conditions below:

• Relative Humidity (RH) > 80 % 2 hours• Relative Humidity (RH) 70 - 80 % 3 hours• Relative Humidity (RH) < 70 % 4 hours

Pipes delayed beyond this point or pipes showing any visible rust stain, shall be blast cleanedagain.


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4.1.5 The field joint surface shall be inspected immediately after blast cleaning and any feature ofthe steel surface such as weld spatter, scabs, laminations or other imperfections consideredinjurious to the coating integrity, made visible during blast cleaning, shall be reported to theCompany Representative and on permission from Company Representative, such defects shallbe removed by filing or grinding. Pipes affected in this manner shall be then re-blasted cleanedif the defective area is larger than 50 mm in diameter.

4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered. Unboundedportions of the coating shall be removed and then suitably trimmed. Portions where parentcoating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas ofthe line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface ofuncontaminated factory applied coating.

4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the coating inorder to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter.All these substances shall be removed before coating, to the procedures herein described.

4.1.8 Protection coating shall be applied on the joints immediately after the completion of cleaningoperation.

4.2 APPLICATION PROCEDURE FOR HEAT SHRINK WRAPAROUND SLEEVES

In addition to the requirements stated above, following shall be complied with:

4.2.1 The wrap around sleeve shall be of a size such that a minimum overlap of 50 mm is ensured(after shrinking) on both sides of the yard applied corrosion coating of pipes.

In the cases where carrier pipe is installed by direct boring/jacking, the overlap on the millcoating for the leading edges of the joints shall be minimum 200 mm. When this extra overlapis achieved by providing an additional patch of heat shrink tape/wraparound, it shall be appliedin such a manner that the square edge of the patch on the joint coating is in the directionopposite to the direction of boring / jacking.

4 2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated either with atorch moved back and forth over the surface or by induction heating. The minimum pre-heattemperature shall be as recommended by manufacturer and shall be checked by means ofcontact type temperature-recording thermometer (Digital Pyrometer with flat probe typecontact). Temperature indicating crayons shall not be used. Pre-heat temperature shall bechecked on every joint. Care shall be taken to ensure that the entire circumference of the pipeis heated evenly. Temperature measuring instruments shall be calibrated immediately beforethe start of the works and thereafter at intervals recommended by the manufacturer of theinstrument.

4.2.3₃ Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet filmthickness 200 microns or as per manufacturer's recommendation whichever is higher, to coverthe exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipecoating if recommended by the manufacturer. The wet film thickness of the primer shall bechecked on every joint with a wet film thickness gauge prior to installation of sleeve.Thickness gauge shall be calibrated once per shift.


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4.2.4 Immediately after application of epoxy primer, when the epoxy is still wet, the wraparoundsleeve shall be entirely wrapped around the pipe when the epoxy is still wet.. Sleeve shall bepositioned such that the closure patch is located to one side of the pipe in 10 or 2 O'clockposition, with the edge of the undergoing layer facing upward and an overlap of min. 50 mm.Gently heat by appropriate torch the backing and the adhesive of the closure and press itfirmly into place.

4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to startshrinkage of the sleeve beginning from the center of the sleeve and heat circumferentiallyaround the pipe. Continue heating from the center towards one end of the sleeve until recoveryis completed. In a similar manner, heat and shrink the remaining side. Shrinking has beencompleted when the adhesive begins to ooze at the sleeve edges all around the circumference.

The complete shrinking of the entire sleeves shall be obtained without undue heating ofexisting pipe coating and providing due bonding between pipes, sleeve and pipe coating. Theinstalled sleeve shall not be disturbed until the adhesive has solidified.

4.4 Pre-Qualification of Field Joint Coating System

The field joint coating system materials and the procedures proposed by the Contractor shall bepre-qualified during the sleeve installation start-up phase. Five joints (5) shall be coated withthe requirements of this specification and then inspected and tested in accordance with therequirements of this specification with respect to the following:

(i) Surface preparation, cleanliness, roughness profile and dustcontamination

(ii) Pre-heat temperature (as applicable)(iii) Primer thickness(iv) As applied coating thickness(v) Holiday detection(vi) Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and at over

laps (as applicable). If required to achieve the temperature of (+) 60°C, suitable thermalblanket may be used.

(vii) Visual appearance and void after installation on the body, area adjoining the weld andarea adjoining the factory applied coating. (To establish voids adjoining the weld andfactory coating, a strip of 50 mm wide and 200 mm long shall be stripped andexamined.)

Company Representative shall witness the tests and inspection. Regular application of fieldjoint coating shall commence only upon successful completion of the pre-qualification testing.

After successful completion of the pre-qualification testing as above, the entire field jointcoating shall be removed, the pipe surface re-blasted and field joint coating re-applied as perthe requirements of this specification.


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5.0 INSPECTION AND TESTING

5.1 Visual Inspection

Visual inspection of the as applied coating shall be carried out on every joint, for the following:

(i) Mastic extrusion on either ends of the sleeve shall be examined(ii) There shall be no sign of punctures or pinholes or bend failure. The external appearance

of the sleeve shall be smooth, free of dimples, air entrapment or void formation. Allsleeves shall be tested for the presence of voids by knocking on the sleeves. A hollowsound compared to the remainder of the sleeve may indicate the presence of voidsunder the sleeve. Such sleeve shall be tested for adhesion at the discretion of theCompany Representative.

(iii) Weld bead profile shall be visible through the sleeve(iv) Visual indicator provided on the backing and the closure patch showing desired heat is

achieved.

5.2 HOLIDAY INSPECTION

The entire surface of each joint shall be inspected by means of a full circle holiday detectorapproved by Company, set to a DC voltage applicable as per the requirements of factoryapplied mainline coating specification of Company. Inspection of the sleeves shall beconducted only after the joint has cooled below 50°C. The holiday detector used shall bechecked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be indirect contact with the surface of coating to be inspected.

No field joint shall be covered or lowered in the trench until it has been approved by theCompany.

5.3 AS-APPLIED COATING THICKNESS

Coating thickness shall be checked by non-destructive methods for each field joint. Averagethickness of the as-applied coating on pipe body shall be established based on measurements atmin. eight locations i.e four measurements on either side of the girth weld at 3, 6, 9 & 12O'clock positions. To establish the minimum thickness on the girth weld, four measurementsshall be taken on apex on the weld at 3, 6, 9 & 12 O'clock positions. All such measurementsshall be recorded. Company Representative reserves the right to ask for additionalmeasurements at any location on the field joint coating, whenever doubt arises.

5.4 PEEL STRENGTH TESTING

5.4.1 One out of every 50 joint coatings or one joint coating out of every day's production,whichever is stringent, shall be tested to establish the peel strength on steel and factory appliedcoating. Contractor shall carry out such testing in the presence of Company Representative.

5.4.2 From each test sleeve selected as above, one or more strips of size 25mm x 200 mm shall becut perpendicular to the pipe axis and slowly peeled off.


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The required peel strength shall meet the requirements of this specification as applicable for(+) 23 °C or (+) 60 °C 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 baremetal, otherwise, test shall be considered failed. The adhesive layer that remains on the pipesurface shall generally be free of voids resulting from air or gas inclusion. In case the peelstrength test at a different temperature than that specified is warranted due to the ambient siteconditions, then the peel strength shall comply the recommendation of the manufacturer.Manufacturer shall be asked to furnish peel strength values corresponding to various expectedtemperatures, prior to start of the works.

5.4.3 If the sleeve does not meet the requirements of clause 5.4.2, the adjacent two sleeves shall alsobe tested. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeveevery twenty-five until Company's Representative is satisfied. The test rate can then be reducedas per clause 5.4.1 at discretion of Company's Representative. If either or both of the adjacenttwo sleeves do not meet the requirements of clause 5.4.2, the field coating shall be stopped.

5.4.4 Company Representative reserves the right of 100% removal of sleeves if he is not convincedthat the requirements of clause 5.4.2 are achieved.

6.0 REPAIRS

6.1 If a field joint is detected to be unacceptable after testing as per section 5.0 of thisspecification the Contractor shall, at his own cost:

(i) Determine the cause of the faulty results of the field coating.(ii) Mobilize the expert of manufacturer, if required.(iii) Test to the complete satisfaction of Company, already completed field coatings.(iv) St

op the field coating works until remedial measures are taken against the causes of suchfaults, to the entire satisfaction of the Company.

6.2 Contractor shall replace all joint coating found or expected to be unacceptable as per section5.0 of this specification.

6.3 Contractor shall, at his own cost repair all areas where the coating has been removed fortesting by the Company.

6.4 After the coating work on welded joints and repairs to the coating have been completed thecoating shall be tested with a spark-tester before lowering or jacking the pipeline.

6.5 Company shall be entitled to check the coating on buried pipelines or parts of pipelines withequipment such as the "Pearson Meter" and the resistance meter. If coating defects areestablished, the Contractor shall be responsible for excavation at such points, repairing thecoating, spark testing and backfilling the excavations without extra charge.


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7.0 DOCUMENTATION

7.1 Prior to procurement of coating materials, Contractor shall furnish the following informationfor qualification of the Manufacturer and material:

a. Complete information as per clause 3.2 and DIN EN 12068 along with descriptiveTechnical catalogues.

b. DVGW Test certificates and results of previously conducted tests, for all properties listedin clause 3.2 of this specification. DVGW report should indicate part nos of the heat shrinksleeve and epoxy.

c. Reference list of previous supplies, in last 5 years, of the similar material indicating theproject details such as diameter, quantity, operating temperature, year of supply, projectname, contact person and feedback on performance.

Once the Company's approval has been given, any change in material or Manufacturer shall benotified to Company, whose approval in writing of all changes shall be obtained before thematerials are manufactured.

7.2 Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish thefollowing documents:

a. Test certificates/results as per Manufacturer's Quality Control Procedure for each batch ofmaterials.

b. Specific application instructions with pictorial illustrations.c. Specific storage and handling instructions.

7.3 All documents shall be in English language only.

3.1.1 HEAT SHRINKABLE WRAP AROUND SLEEVES FOR HDD CROSSINGS:

Field joint anti-corrosion coating material for 3LPE coated pipelines laid by HDD methodology shallbe fiberglass re-enforced radiation cross linked heat shrinkable wraparound sleeve- DIRAX (Seal ForLife) or equivalent for a maximum operating temperature of (+) 60°C (T max) and shall conform todesignation EN 12068 - C HT 60 UV. In addition, the field joint anti-corrosion coating shall comply therequirements specified in para 3.2 of this specification.

a) For HDD Joint Coating fiberglass re-enforced radiation cross linked heat shrinkablewraparound sleeve certified to Stress class C60-HT UV as per EN 12068.

b) A solvent-free, two component liquid epoxy primer.c) A specifically designed wear cone.

Pipe Size(Specified Outside Diameter)

Thickness (mm)

On Pipe Body(Min)

On Weld Bead(Min.)


P.013828D 11077

208


All Diameters 3.0 2.8

Functional Requirements of Field Joint Coating

3.2.1 Properties of the Fiber Glass re-enforced radiation cross linked PE backing shall be as follows:

Sr.No Properties Unit Requirement Test method

a. Bursting Strength @ +25°C N ≥ 2000N EN 12068

b. Dielectric withstand with 1000Volts/sec

KV ≥30 ASTM D 149

c. Water absorption,@+25°C for 24 hours

% <0.05 ASTM D 570

d. Volume Resistivity@ +25°C

Ohm-cm ≥1015 ASTM D 257

f. Shore D Hardness Shore D ≥55 ASTM D 2240

3.2.2 FUNCTIONAL PROPERTIES OF JOINT COATING SYSTEM (AS APPLIED)

As applied field joint coating system shall comply the requirements of DIN EN 12068, Table1 and 2 corresponding to designation DIN EN 12068 - C HT 60 UV, except as modifiedbelow:

a. Cathodic Disbondment Resistance at T. i.e 60°C shall be 10 mm when tested as perAnnexure K of DIN EN 12068.

b. Bursting strength should be greater than 2000N as per the test indicated in EN12068.c. Peel Strength shall be as follows:

Peel Strength UnitRequirement forMech. ResistanceClass C (minimum)

Test methodas per

DIN EN 12068

To Pipe Surface@ 23°C N/mm 10

Annexure C@Tmax N/mm 1.5

To Factory Coating@ 23°C N/mm 10

@Tmax N/mm 2.0

NotesTmax shall be (+)60°C


P.013828D 11077

208


Balance all other requirements shall be as per specification for the main line field joint coating.

PTS - PIPELINE VALVESP.013828D 11077

209

Page 1 of 19



PTS – PIPELINE VALVES



PIPELINE VALVESP.013828D 11077

209


TABLE OF CONTENTS

1. SCOPE ........................................................................................................................................ 3

2. DEFINITIONS............................................................................................................................. 3

3. PRELIMINARY STATEMENT ....................................................................................................... 3

4. GENERAL.................................................................................................................................... 4

5. CODES, NORMS AND STANDARDS............................................................................................. 4

6. DESIGN AND CONSTRUCTION................................................................................................... 5

7. MATERIALS .............................................................................................................................. 10

8. FABRICATION AND TEST.......................................................................................................... 11

9. MARKING ................................................................................................................................. 14

10. INSPECTION............................................................................................................................. 15

11. PAINTING AND COATING......................................................................................................... 16

12. SPARES AND ACCESSORIES ..................................................................................................... 17

∑ ∑ ∑


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1. SCOPE

This Document (PTS - Particular Technical Specification for – PIPELINE VALVES) lists the Specification for

Manufacturing of Ball Valves, for the pipeline project for the service of natural gas.

The present specification has to be read in conjunction with General Technical Specification

70000/740/GTS/402 rev. 7 (The GTS) which it amends and/or complements.

The present specification can confirm, complete or modify certain sections/paragraphs of said «General

Technical Specification». The PTS will govern the requirements for all such sections.

Add:

The present Particular Technical Specification relates to the manufacture of “Pipeline Ball Valves” (for

above and underground) for the pipeline project for the service of natural gas.

2. DEFINITIONS

Client shall mean GAIL (I) Limited

Manufacturer means the Manufacturer of the Valves as well as its sub contractors.

EPC Contractor/Contractor The party which carries out all or part of Engineering, Procurement,

Construction, Pre-commissioning & Commissioning of the project. It shall

mean EPC Contractor in the present context.

Inspection Agency or Third means the Inspection Agency to be appointed by the EPC Contractor

Party Inspection Agency (TPIA)

Consultant /Owner Shall means TRACTEBEL Engineering Pvt. Limited / The entityRepresentative of the purchaser or the company nominated by the purchaser to design the

natural gas transport or distribution system and to specify the equipment.

PTS means the present “Particular Technical Specification P.013828 M 11077 209”

and all its appendices, if any.

GTS means <<General Technical Specification 70000/740/GTS/402 rev. 7 >>

and all documents it refers to.

3. PRELIMINARY STATEMENT

Add:

• In case of conflict between the requirements in technical documents, the most stringent requirements

shall apply.


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• A valid copy of API 6D monogram/certificate shall be included in the offer.

Modify para 10 & 11:

• For any control, test or examination required under the supervision of the Authorised Control authority

(LOFC Intervention points included), the latter shall be informed in writing FIVE (5) working days in advance

by the Manufacturer (Fifteen working days in case of supply of foreign origin) about place and time with a copy

to the Client/Engineer. Wages and travel expenditure of the Authorised Control Authority are at the Client’s

expenses.

• As the manufacturing is to be carried out under LOFC concept, the Manufacturer shall send for approval a

List of Operation in Manufacturing and Control (see annex 1) to the Authorised Control Authority and Client,

TEN (10) working days before manufacturing. This list shall be in conformity with the annex 1 to this

document. Before starting any manufacturing, the Manufacturer shall be in possession of this approved

document, filled in with all intervention points.

4. GENERAL

Add:

Valve design shall meet the requirements of API Specification 6D and shall be suitable for the service

conditions indicated in the Valve Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII,

Division 1 shall be used to design the valve body.

Allowable stress requirements shall comply the provisions of above code. In addition, corrosion allowance

indicated in Valve Data Sheet shall be considered in valve design.

The manufacturer shall have valid license to use API monogram on valves manufactured as per API 6D. The

ball valves shall be bi-directional.

5. CODES, NORMS AND STANDARDS

Add:

API 598 : Valve Inspection and Testing

ISO/DIS 14313 : Petroleum and Natural Gas Industries - Pipeline Transportation Systems –

Pipeline valves

Note:

In case of conflict between the requirements of this specification, Codes, Standards and Specifications referred in

above, the most stringent requirement specification shall govern.


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6. DESIGN AND CONSTRUCTION

6.2 Design

6.2.2 Welding ends

Add:

The valve manufacturer shall supply all butt weld valves with a welded pups/Transition piece at both ends which

shall be considered as an integral part of the valve & hence such as strength test, hydrostatic test & Leak test

should be done with pup-piece/transition piece weld on valve.

The chemical composition of the steel of the Pup/Transition piece meets the following requirements

Maximum limit of chemical elements which may be used in material under this Particular Technical

Specification.

% maximum % maximum % maximum

C 0.230 Mn 1.60 Si 0.50

P 0.030 S 0.025 Nb. 0.080

V 0.120 Mo 0.250 Nt 0.015

Alternate alloy elements may be used but they shall be discussed with the user prior to delivery of the material.

This table is not intended to represent the composition of any heat of steel, but merely to record the maximum

permissible amounts of one element. The combination of elements of any heat must conform to the carbon

equivalent, computed like following:

Carbon equivalent shall be computed by "check analysis", the following equation is applicable:

and shall not exceed 0.40 % . The CE (IIW) limits shall not apply if C< 0.12% and shall not exceed 0.43

For each heat the manufacturer shall analyse the following elements: C, Mn, Si, P, S, Nb, V, Cr, Mo, Ni and Cu.

The intentional addition of elements other than those specified is not permitted unless agreed up by the Client.

In any case, for unintentional additions, the following limitations shall be respected:

Cr < 0.15% Mo < 0.05% Cu < 0.20%


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Ni < 0.30% Co < 0.01% Al < 0.07%

The content of N total (Nt) may be up to 0.0150% and must be guaranteed by the manufacturer. If the

manufacturer cannot give any guaranty of N content, he shall analyse this element.

The total content for Nb + V will be limited to 0.150%.

In grades X42 through X70 for each reduction of 0.01% below the maximum carbon content, an increase of

0.05% manganese above the specified maximum is permissible, up to a maximum of 1.70%.

The choice and use of alloying elements made from high strength low alloy steels to give the tensile properties of

API 5L Gr. X70 (in table hereafter), is of the responsibility of the manufacturer.

Symbol Yield Strength (min.) Tensile Strength (min.) Elongation in 2 in.

Ksi Mpa Ksi Mpa Min. percent

X70 70.30 485 82.70 570 20

The ratio of effective yield strength to effective tensile strength of the steel shall not exceed 0.90 for material of

SMYS 70300 psi. For SMYS below 70300 psi this ratio shall not exceed 0.85.

If the butt-welding end of the valve has a thickness and/or a steel grade not equal to the connecting pipe, butt-

welding ends shall be in accordance with any of the suggestive figures given in Appendix I of ASME B 31.8 or

an appropriate combination selected by the valve manufacturers to ensure that availability of uniform pig passage

without sacrificing pressure-temperature design requirement.

Butt weld end valves shall be provided with pup piece. Pup piece length shall be of at least 2.0 D for size below

6” and 300 mm for 6” and above size valves upto 18”.

Size of Ball valve (NB) Pup Piece length (mm)Below 6” 2.0 D

6” & Above upto 18” 300

No repair is permitted on pup pieces. 100 % UT shall be performed on pup pieces.

Thickness of Pup Piece shall be determined by the Vendor as per Code requirements. The pipe end of the Pup

Piece shall match the Material, diameter and thickness of line pipe where the valve is required to be welded.

Table below indicate the size, thickness, material of the line pipe for various sizes of Ball valves:


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Size of Ball valve

(NB)

Material of pipeline

and piping

construction

Thickness Remarks

12’’ API 5L X 70, PSL 2 Note - 1 Main line Station

Piping12’’ API 5L X 70, PSL 2 Note - 1 Hot Induction Bends

at Station

3” to 10” ASTM A 333 Gr. 6 SCH. 80 Seamless (LTCS)

½” to 2” ASTM A 333 Gr. 6 SCH. 160 Seamless (LTCS)

Note – 1 : Refer pipeline Design basis ( Document No.: P.011947 D 11017 001)

The Valve Manufacturers shall submit all necessary details regarding welding of BW end of valve with

Line pipe along with calculation for provided thickness for approval of Owner/Owner’s representative.

The Charpy V-notch impact testing of pup piece (for API 5L material) as indicated in data sheet shall be carried

out as following:

Location Impact TestTemp.

Impact Energy Absorption ValueAvg. Value Individual Value

For Base

-20 °C 35 J 28 J

0 °C 100 J 80 J

For Weld & HAZ Metal

I

-20 °C 35 J 28 J

0 °C 40 J 32 J

In addition to above the Charpy V-notch impact testing of pup piece, Valve body and other pressure containing

parts of valve (for CS or LTCS steel material) as indicated in data sheet / piping material specification shall be

carried out as per following requirements

Material Test Temperature Energy Absorption Value

(Minimum)Carbon Steel

Material

-20 Deg. C Individual 28J & Average35J

Low TemperatureCarbon Steel

Material

-20 Deg. C Individual 28J & Average35J

Material Standard’ impacttest requirements

temperature or - 45 Deg.C whichever is lower

Material Standard’s Impacttest requirement


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The pup piece shall be subjected to all the testing (Charpy, Tensile, Hardness, NDT etc.) requirements as

mentioned in QAP. Inspection frequency, acceptance criteria & reference standards shall be as per

applicable specifications/QAP.

6.2.4 Design features

Add in Para 1:

For above ground valves, body design shall be either fully welded or bolted type. For buried valves, valve body

design shall be fully welded type only. Valve body joints with threads are not permitted. In the valve body outlets

also, threading is not permitted.

Ball shall be of single piece, solid type construction.

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 ball movement

is not impeded. Also, when the full bore ball valve is in fully open position, the ball shall not obstruct the passage

of flow/pig run. Manufacturer shall demonstrate the same through manual and actuated operation.

Modify:

For 4” & above size, valve shall be trunnion mounted ball valve. All trunnion mounted ball valve shall be fitted

with following devices:

Double piston effect: when the pressure is applied to one side, let us say upstream” side, and when upstream ball

seat is leaking, transfer pressure shall have a positive shut-off effect on the downstream seat (acting, for instance,

on the back face of this seat) and thus reinforcing the global tightness of the valve. (Not applicable)

Add :

Vent, sealant etc. shall be adequately supported on the stem and body using clamps

Corrosion allowance of ball valve shall be 2.0 mm

For valves with primary metal to metal contact and secondary soft seats, 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 of valve at maximum differential pressure

corresponding to valve class rating. The seat rings shall be so designed as to ensure sealing at low as well as high

differential pressures.


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For soft seated valves seat rings may be provided with soft insert. The same shall be positively locked in position.

All such ball valves shall comply fire safe design and qualified by fire testing as per API 6FA specification for

Fire test for valves.

Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar(a) in both open and

closed positions.

Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high alloy steel

components. Suitable insulation shall be provided, if required.

Valve design shall ensure repair of stem seals/packing under full line pressure.

Valve shall be provided with ball position indicator and stops of rugged construction at the fully open and fully

closed positions

6.2.5 Auxiliary Connection

Add / Modify :

Schematic for drain vent and stem /Sealant point for “Above Ground Installation” and “Under Ground

Installation” refer Appendix – I.

6.2.6 Stem extension for underground valve

Add:

Stem extension material shall be equivalent to stem material or as indicated in the data sheets for below ground

valves. Stem shall be single piece construction & no joints are permitted. The length of stem extension shall be as

indicated in the MR.

Valves provided with stem extension shall have water proof outer casing. Length of stem extension shall be as

indicated in Valve Data Sheet. The length indicated corresponds to the distance between centreline of the valve

opening and the top of mounting flange for valve operating device (gear operator/power actuator as applicable).

Outer casing of stem extension shall have ⅜”" or ½" NPT plugs at the top and bottom, for draining and filling

with oil to prevent internal corrosion. Outer casing material shall be ASTM A333 Gr. 6 & thickness shall be

minimum Sch 160 for 2” and below.

6.3 OPERATION

6.3.1 Add:

Valves shall have a Gas over Oil (GOO) actuator or manual operator or hydraulic operator as indicated in the

Valve Data Sheet. All mainline valves shall be equipped with Gas over Oil (GOO) actuators except where

specifically indicated otherwise. Valves of size, DN upto 100 mm (4”) shall be wrench operated, valves of size DN


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150 mm (6”) to DN 300 mm (12”) shall be gear operated and valves of sizes above DN300 mm (12”) shall be

hydraulic operated unless otherwise indicated in the valve data sheets. Actuated valve shall also have hand wheel

for manual operation. Each wrench-operated valve shall be supplied with wrench. 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 power

cylinder and that damaged parts can be replaced without the valve cover being removed.

The Gas over Oil (GOO) actuator shall be in accordance with the specification issued for the purpose and as

indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Process Data Sheets for

valves / Material Requisition. 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’s

rated torque output shall be 1.25 times the break torque required to operate the ball valve under the maximum

differential pressure corresponding to the Valve Class Rating.

Valves shall be subjected to Operational Torque Test as per API 6D (Annexure B) under hydraulic pressure equal

to maximum differential pressure corresponding to the applicable ANSI class rating of valve.

6.3.2 Add :

Manufacturer shall also indicate the number of turns of hand wheel in case of gear operators (along with their

offer) required for operating the valve from full open to full close position.

When indicated in Material Requisition, valves shall have locking devices to lock the valve either in full open

(LO) or full close (LC) positions. Locking devices shall be permanently attached to the valve operator and shall

not interfere with operation of the valve.

6.3.9 Add:

No casting is permitted for stem and stem extension material of all valves. 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 for a minimum of 500 open-close-open cycles for a design life of

40 years. The combined stress shall not exceed the maximum allowable stresses specified in ASME section VIII,

Division 1. For power actuated valves, the valve stem shall be designed for maximum output torque of the selected

power actuator (including gear box, if any) at valve stem

7. MATERIALS

7.2 Pressure Retaining Parts

Modify clause no. 7.2.1 as below:

Bodies, including end flanges and welding ends (other than for field welding), bonnet and covers of valves shall be

made in material conforming to API 6D spec. (or another material specification accepted by the Client/Engineer)

and be furnished with certificates EN 10204-3.2 stating the quality, the mechanical properties (yield strength,


209


tensile strength, percent elongation, impact test value at the temperature specified under per Section 8.4.2 of

GTS) the chemical analysis, the manufacturing process and the marking (e.g. the heat number) of the steel. These

certificates shall be added to the CMTR.

7.2.4 Modify:

· The carbon equivalent shall not exceed 0.43

· Add:

In case of LTCS material of Ball and Seat Ring, ENP coating of 75 micron shall be applied as per ASTM

B733-15. Minimum hardness of plating 48-50 HRC (as plated) and 62-63 HRC (after heat treatment).

· Modify:

The ratio of yield strength to tensile strength shall not exceed 0.90.

7.3 Bonnet, Cover and Body Bolting

Modify first paragraph as below:

Bonnet flange cover and body bolting shall be in conformance to ASTM A320 Gr. L7. Nuts shall conform to

ASTM A194 Gr.4/Gr. 7. All bought out items shall be procured with certificates EN 10204-3.2 including Valve

actuator. These certificates shall be added to CMTR.

Add:

All studs and nuts shall be hot dip zinc coated.

7.4 Non – Metallic Parts

Add:

Non-metallic parts of the valves (including O-rings, soft seals etc.) intended for hydrocarbon gas service shall be

resistant to explosive decompression.

7.6 Sour Gas Service

Not Applicable

8. FABRICATION AND TEST

Prior to manufacturing a meeting shall be organised between EPC Contractor, vendor/contractor, TPIA appointed

by EPC Contractor and Owner.


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8.1 Welding Fabrication

Replace third point by:

The joints shall be furnished in accordance with the requirements of Section VIII of ASME Boiler and

Pressure Vessel Code - Division 1 and Section IX.

Add:

Vendor shall provide detail instruction for carrying out welding; pre heating etc and testing of weld joints between

pipe and valves at site. Vendor shall depute engineer for welding instruction at site

8.3 Heat Treatment

Add

Chemical composition and mechanical properties shall be checked as per this specification and relevant material

standards, for each heat of steel used. All testing frequency shall be as per Inspection & Test Plan/ QAP. Heat

treatment chart for forging material shall be witness & start/stop time signed by TPIA.

8.4.2 Impact test

Charpy V-notch test on each heat of base material shall be conducted as per API 6D-Clause 8.5, for all pressure

containing parts such as body, ball, seat, stem, end flanges and welding ends as well as bolting material for

pressure containing parts. The Charpy V-notch test requirements of applicable material standard shall be

conducted. The impact test temperature shall be lower of the temperature specified in material standard and -45C.

8.5 Non-Destructive Examinations (NDE)

The following non-destructive examination shall be performed by the Manufacturer under the supervision of

the TPIA and the certificates shall be added to the CMTR.

8.5.1 List of NDE

Add :

· Body castings of all valves shall be radiographically examined as per ASME B16.34. Procedure and

acceptance criteria shall be as per ASME B16.34. The extent of the radiography shall be 100% for

all class rating of all sizes.

· Radiography shall be performed after the final heat treatment also.


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· Internal surfaces for all castings shall be 100% wet magnetic particle inspected. Method and

acceptance shall comply with ASME B16.34.

· All valves made by forgings shall be ultrasonically examined in accordance with the procedure and

acceptance standard of Annexure E of ASME B16.34. Body fabricated from plates is not acceptable.

· Internal surfaces of all forgings shall be 100% wet magnetic particle inspected. Method and

acceptance shall comply with ASME B16.34.

· Full inspection by radiography shall be carried out on all welds of pressure containing parts including

· 100% radiography of the weld joint between valve and pup pieces. Acceptance criteria shall be as per

· ASME B31.8 and API 1104.

· Welds & valve body weld joints, which in Company's opinion cannot be inspected by radiographic

methods, shall be checked by ultrasonic or magnetic particle methods and acceptance criteria shall

be as per ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively.

8.6 PRESSURE TESTING

8.6.5 Add

In addition to pneumatic testing and functional testing shall be carried out at 90 bar (g) and 7 Bar for 600# &

300 # pressure rating valves, using nitrogen for 5 minutes.

In addition to above the helium leak test shall be carried out as per ASME Sec. V, Subsection A, Article 10

(Detector Probe Technique), Appendix IV. Helium leak testing shall be done at 25% of rated pressure for 30 mins.

8.7 OPERATIONAL TORQUE TEST

GOO actuated & Hydraulic operated valves shall be tested after assembly of the valve and actuator, at the valve

Manufacturer’s works. At least five Open-Close-Open cycles without internal pressure and five Open-Close-Open

cycles with maximum differential pressure corresponding to the valve rating shall be performed on the valve

actuator assembly. The time for Full Open to Full Close shall be recorded during testing. If required, the actuator

shall be adjusted to ensure that the opening and closing time is within the limits stated in Process Data Sheets for

valves.

Hand operator provided on the actuator shall also be checked after above testing, for satisfactory manual over-ride

performance.

The above tests shall be conducted on all valves.


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8.9 ANTI-STATIC DEVICE TESTING

“If requested in the purchase order, all ball valves shall be submitted of to an anti-static electricity testing in

accordance with BS 5146 and this certificate shall be added to the CMTR”.

Subsequent to successful testing as specified in above clause, one (1) valve per size out of the total ordered

quantity shall be randomly selected by the EPC Contractor / Owner / Owner’s Representative for cyclic testing as

mentioned below:

a) The valve shall be subjected to at least 100 Open-Close-Open cycles with maximum differential pressure

corresponding to the valve rating.

b) Subsequent to the above, the valve shall be subjected to hydrostatic test and supplementary air seat test.

Air seat test shall be carried out at 7 barg and not 6 barg as mentioned in GTS.

In case this valve fails to pass these tests, the valve shall be rejected and two more valves of same size shall be

selected randomly and subjected to testing as indicated above. If both valves pass these tests, all valves

manufactured for that size (except the valve that failed) shall be deemed acceptable. If either of the two valves fails

to pass these tests, all valves of that size shall be rejected or each valve shall be tested at the option of

manufacturer.

Previously carried out test of similar nature shall be considered acceptable if the same has been carried out by

Manufacturer in last two years. Valves of same size and rating previously tested shall be qualified.

9. MARKING

Add:

All valves shall be marked as per API 6D. The units of marking shall be metric except nominal diameter, which

shall be in inches.

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 Moly coat type 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

On packages, following shall be marked legibly with suitable marking ink:

a) Order Number

b) Manufacturer's Name


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c) Valve size and rating

d) Tag Number

e) Serial Number

10. INSPECTION

10.1 Information

Add:

In case of supply from foreign origin, the Manufacturer shall inform the Control Authority min. fifteen (15)

working days in advance of any intervention required by this specification and shall send a copy of it to the

Client/Engineer (by fax).

Valve’s certification requirements shall comply with European Standard EN 10204 (latest edition) 3.2Certificate.

Add:

PACKING

Ball valves are to be suitably packed, crated (seaworthy crate in the case of foreign vendors) and handled properly

to prevent damages or deteriorations during transportation by sea (in the case foreign vendors) and road to the

designated ware houses (as detailed in the commercial volume of the tender).

Vendors shall submit drawings and details of the proposed packing / crating method clearly indicating the

following:

· Secure bolting arrangement of the ball valve to the robust base of the crate for packing.

· Lateral staying arrangement to prevent movement of the valve inside the crate resulting damage during

transportation and handling.

· Also all extended parts such as drain and vent piping shall be securely supported to the valve body to

prevent damage during transportation and also subsequent installation and use in operations

10.2 Documents

Add:

EPC shall obtain the following documents from manufacturer and verify before placement of order:

· General arrangement/ Sectional drawing & blow-up drawing of seat assembly shall be submitted.


209


· Number of turns for Gear Operated valves shall be indicated in the GA or shall be furnished separately.

· Torque curves for the power actuated valves along with the break torque and maximum allowable stem

torque.

· Copy of valid API 6D Certificate.

In case of soft seated valves, copy of Fire Safe Test certificate of qualifying valve as per API 6FA carried out in

last 10 years shall be furnished.

Details of support foot including dimensions and distance from valve centerline to bottom of support foot.

11. PAINTING AND COATING

Following coating specification shall be followed:

11.1 Underground Valves:

The external coating for underground valves shall be made of solvent free PUR / min. 1000 microns

(Final Paint DFT) thickness in two layers Polyurethane as per code DIN 30677/2 (Type DIN 30677/2-

PUR-50) alternatively high build epoxy corrosion protection coating with minimum 500 microns final

DFT as per DIN 30677/2 is also acceptable.

For repair it would be as per manufacturer’s recommendations which have to be approved by

Owner/Engineer.

11.2 Aboveground Valves:

The surface of the valve will be shot-blasted SA 2 1/2 (Swedish standard SIS 055900). Before painting,

the valve shall be cleaned from grease and dirt. The painting shall be as per ISO12944-5-2007 (Table

A-5) Paint System No. S5.14 with durability C-5 (I) Very High Industrial. The final paint DFT shall be

minimum 300 micron.

The nature of the products shall be specified in the offer and shall guarantee a corrosion protection for a

storage period in a shop for at least one year.

Painting in accordance with Client/Engineer's specifications.

Painting and coating procedures shall be submitted for approval before manufacturing to the Control

Authority and to the Client / engineer.


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12. SPARES AND ACCESSORIES

All spares required for start-up and commissioning of the valve shall be supplied along with the valve.

Manufacturer shall furnish list of recommended spares and accessories required for two years of normal

operation and maintenance of valves and price for such spares shall be quoted separately.

∑ ∑ ∑


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Σ Σ Σ

PTS - STATION PIPEP.013828D 11077

210

Page 1 of 14

VENDOR LOGO

IRCA LOGO



PTS - STATION PIPE

(ASTM A 333 Gr. 6 and API 5L Gr. X52, X65 & X70, PSL 2)




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TABLE OF CONTENTS

1. GENERAL.................................................................................................................................... 3

2. DESIGN AND CONSTRUCTION................................................................................................... 5

3. MATERIALS ................................................................................................................................ 5

4. PRELIMINARY CONDITIONS FOR UPGRADING TO 3.2. CERTIFICATE...................................... 6

5. UPGRADING TESTS .................................................................................................................... 8

6. INSPECTION AND CERTIFICATION ......................................................................................... 11

7. INSPECTION BY CONTROL OPERATIONS: L.O.C. .................................................................... 12

8. CORROSION INSPECTION ....................................................................................................... 13

∑ ∑ ∑


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1. GENERAL

This specification describes the requirement of station pipes to be used for installation at proposed stationfacilities along the above pipelines, viz. the dispatch station, SV station, receiving station, and threecustomer stations.

This specification also describes the examinations and upgrading tests to be performed on carbon steel pipestaken out of stock.

The pipes have to be delivered in accordance with this particular specification:

Codes, Norms and standards (latest revision) listed below (but not limited to):

ANSI B31.8 Gas transmission and distribution piping systems

ANSI B16.25 Butt welding ends

ANSI B36.10 Welded and seamless wrought steel pipe

ASTM A 333 Seamless and welded steel pipe for low temperature service

ASTM A 370 Mechanical testing of steel products

ASTM E 112 Standard test methods for determining the average grain size

ASME Boiler and Pressure Vessel code

EN 10204 Metallic Products : Type of Inspection Documents

ISO 9001 Quality management standard

ISO 148 Determine the impact strength of steel and energy absorbed by Chapy V-notch.

API 5L Specification for line pipe

The present specification can confirm, complete or alter certain criteria / requirements / acceptance normsof applicable codes, standards and/or specifications.

In his offer, the vendor/contractor shall specify all proposed modifications or alternatives to the presentspecification. In all cases, each modification has to be submitted to the Owner / Owner’s representative foracceptance and approval. The complete upgrading cycle shall be supervised by the TPIA. Allconsequences after eventual order, for non respect of this obligation shall be to the manufacturer's cost andresponsibility.

Before the order is placed, a technical audit could take place with EPC contractor or client.

The manufacturer's specification of the steel, the manufacturing procedure itself and the laboratories inwhich testing takes place, shall be approved and registered by the EPC contractor/ Owner /Owner’srepresentative.

The TPIA shall verify the control equipment of the vendor, its calibration and the points at which it islocated. If during the control of the pipes certain problems arise the TPIA may demand supplementarytests.


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At all times while work on the contract of the purchaser is being performed, the inspector representing thepurchaser shall have free entry to all parts of the manufacturer's facilities and those of all subcontractors,who are involved in the manufacturing and testing of the pipes. All reasonable facilities shall be afforded tothe inspector to satisfy him that the product is being furnished in accordance with these specifications.

All tests and inspections called for by these specifications will be made in the manufacturer's plant prior toshipment and at the manufacturer's expense, unless otherwise stated, and shall be conducted so as not tointerfere unnecessarily with the operations of the manufacturer's plant. The manufacturer shall notify thepurchaser prior to completion or shipment of all items requiring such inspection.

Eventual interpretations and deviations to this specification by the Manufacturer shall be requested bywriting in his offer with detailed justification and approved by the Owner / Owner’s representative beforeeventual order to the Manufacturer. The latter is responsible and shall indemnify the Owner / Owner’srepresentative for any damage resulting from the non-respect of this obligation.

An approval of documents can never be considered as an acceptance of deviations or relaxations torequirements. A deviation is only possible after specific request to the purchaser and its approval.

A valid copy of the ISO 9001 certificate shall be included in the offer.

In case the Pipe is procured from manufacturer, the manufacturer shall inform the TPIA / EPC contractorMIN. 5 working days in advance of any control test or examination under the supervision of the TPIArequired by this specification, and shall send a copy (fax/E-mail) of it to the EPC contractor / Owner’srepresentative.

The Manufacturer shall send for approval a List of Operation in Manufacturing and Control to the Owner /Owner’s representative, TEN (10) working days before manufacturing. Before starting any manufacturing,the Manufacturer shall be in possession of this approved document, filled in with all intervention points.

Glossary

Client / Owner Shall mean GAIL (I) Limited

Manufacturer Means the Manufacturer of the pipe.

EPC Contractor / Contractor The party which carries out all or part of Engineering,Procurement, Construction, Pre-commissioning & Commissioningof the project. It shall mean EPC Contractor in the present context.


Means the Inspection Agency to be appointed by the EPCcontractor



PTS Means the present <<Particular Technical Specification P.013028M 11077 210>> and its entire appendix, if any.


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a) The pressure temperature ratings of the pipes are in accordance with B31.8; the dimension standardshall be in conformance to ANSI /ASME B 36.10.

b) The temperature range as follows:

· For above ground Services – LTCS : -45°C to +65°C

· For above ground Services – CS : -20°C to +65°C

· For Underground Services : -20°C to +60°C

The design pressure is 92 Barg.

c) Wall thickness shall meet the following requirements:

q The maximum allowable stress in the base material and in the weld shall be equal to fifty per cent(50%) of the minimum yield strength guaranteed by the specification of the steel used.

d) The specified pipe wall thickness/schedule and grade (with reference to the equivalent grade in ASTMspec. or API 5L spec.) with which the pipe is intended to be used is specified in the data sheet/pipingclass.

e) The design shall take into consideration performance requirements prescribed in paragraph 2.f.

f) All pipe under this specification shall be designed to withstand a field hydrostatic test pressure withnon corrosive water, after installation, during 24 hours at a following pressure level:

Minimum: P = 1.4 MOP

Maximum: P = 1.5 MOP

Where:

P = hydrostatic test pressure, bar,

MOP = Maximum Operation Pressure

3. MATERIALS

a) The steel used in the manufacture of pipe shall be in conformance to the ASTM / API5L standard.

b) The chemical composition of the steel shall meet the requirements of T a b l e 1 of this specification.

c) The steel used has tensile properties conforming to the requirements prescribed in the ASTMstandard. d) The ratio of yield strength to tensile strength shall not exceed 0.85 for ASTM A 333Gr.6 Pipes and 0.90 for API 5L Gr.X65/70 PSL 2 Pipes.

d) The steel shall be fully killed, fine grain practice.

e) The steel used shall be suitable for field welding to other fittings, pipes, flanges, or valvesmanufactured under ASTM specifications A333, A350, A352, A381, A420, A694, A707 or APIstandards specifications 5L, 6D, 605 or MSS standards SP-44, SP-72, SP-75, EN10208-2 in linewith the Piping Specification attached with the tender document.


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f) If preheating of the material is required to ensure proper weld ability under normal field conditions,the manufacturer shall state so in the offer, specifying preheat requirements and if accepted bythe purchaser, this shall be permanently indicated on the pipe.

g) The manufacturer of pipe must deliver a certificate EN 10204 3.2 stating the quality, themechanical properties (yield strength, tensile strength, percent elongation, impact test as per belowtable, the chemical analysis, the process of manufacture and the marking (for example the heatnumber of material) of the steel.

A new chemical analysis (upgrading) shall be done on a specimen of pipe in presence of theControl Authority; one per heat number, see par. 5.3.

h) Chemical composition:

For each heat the manufacturer shall check a chemical analysis of the steel.

q Check analysis: carbon equivalent shall be computed by the following equation :

C E C Mn Cr Mo V Ni Cu. .= + ++ +

++

6 5 15

and shall not exceed 0.43

4. PRELIMINARY CONDITIONS FOR UPGRADING TO 3.2. CERTIFICATE

Before proceeding to any qualification tests, the pipes shall meet following requirements.

4.1. Material

Carbon steel piping to be supplied according to ASTM A 333 Gr. 6 or API 5L Gr.X52/ X65/ X70 as perPMS.

4.2. Origin of pipes

The origin of pipes shall be mentioned.

The Engineer or/and the Control Authority reserves the right to approve or refuse the origin of pipes.

4.3. Identification

All pipes shall bear the original mill identification.

The marking shall be legible and shall include as a minimum:

l Manufacturer's name or brand.

l ASTM specification.

l Steel grade,

l Heat number or identification number traceable to the certificate.

l Size and schedule number.


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l Process of manufacture.

4.4. Certification

The pipes shall have been manufactured according to material data sheets to ASTM A 333 Gr. 6 or API 5LGr.X 52/ X65/ X70.

A mill certificate according to EN 10204 3.2 shall be supplied and shall mention as a minimum:

l The ASTM specification and steel grade.

l The type of pipe manufacturing process.

l The heat and/or identification number.

l The type of heat treatment.

l The chemical analysis of the heat.

l The mechanical properties as required by the ASTM specification.

The marking on each pipe shall be checked for conformity with the manufacturer certificate.

The content of the certificate shall be reviewed before upgrading take place for conformity with theapplicable ASTM specification.

TEST OFEXAMINATION

REFERENCE NUMBER OF TESTS

Heat analysis ASTM A 333, § 4.3.4, 4.3.5, 6 andTable 2, API 5L

Each Pipe

Tensile test ASTM A 333 § 7, 12.1. Each Pipe

By pipe Flattening test ASTM A 333 § 12.1, Clause 6.2.3 ofthis PTS

10% from lot or Heat

manufacturerEN 102043.2

Impact test ASTM A 333 § 13, 14. At -20 °C - Each PipeAt -46 °C - Each Pipe

EN 10204 –3.2Certificate

Hydrostatic test ASTM A 333, § 15, 15.2. Each Pipe

Hardness test Clause 6.2.4 of this PTS Each Pipe

MicrographicExamination

Clause 6.2.5 of this PTS Each Pipe

Marking ASTM A 333 § 16ASTM A 530 § 26

Each PipeTraceability to be guaranteed ontest report

Visual anddimensionalexamination

ASTM A 530, § 10, 12, 13, 17 Each Pipe

4.5. Preparation of pipes for qualification

All pipes shall be new and the interior and exterior surfaces shall be free of dirt, sand, debris and rust.


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The pipes shall be sorted per specification, per heat number and dimensions.

A lot of pipes prepared for qualification shall only contain pipes of the same:

l Manufacturing process,

l Diameter and schedule,

l Indicated heat number,

l Finishing treatment,

Marked with piping class number and with the Control Authority’s identification stamp on both ends ofeach pipe.

5. UPGRADING TESTS

Before NDT and Destructive tests, all pipes shall be hydrostatically tested as per applicable code / standardsas under 100% witness of TPIA. All Destructive & Non-Destructive Test shall be carried out as perapproved QAP by client/ PMC.

5.1. Visual and dimensional examination

Before any other testing, each pipe length shall successfully undergo a visual and dimensional examination.

The condition of the pipe shall be checked; particularly the external and internal surface aspects(cleanliness).

The dimensions shall be verified (thickness, diameters, out of roundness, straightness) and shall be withinthe tolerance of the specification.

For longitudinal pipes, all test required for the qualification of the welds and the HAZ will be re-donespecifically (tensile test, impact test…).

5.2. Mechanical testing

The mechanical properties shall be verified after acceptance of the pipes as pertaining from one same lot.

The procedure for mechanical testing needs to provide with the required quantities of pipes, as per materialdata sheets and as per prepared lot, the necessary over lengths for removal of testing specimens.

These over lengths are in no way included in the material data sheets.

The nature of mechanical tests to be performed is specified in the applicable ASTM specification. Numberof tests shall be as per ASTM A333 or API 5L Gr. X52/ X65 / X70 specification.

Location and removal of specimens from pipe to be carried-out according to ASTM /API specification.

Test specimens may only be cut after a marking transfer by the TPIA


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The following mechanical tests shall be performed on material of stock (with 3.2); the supervision of theControl Authority delegate and the certificates shall be added to the CMTR.

For carbon steel Pipes, hardness of weld and HAZ shall be 200 BHN (max.).

5.2.1. Tension test

Requirements

The material shall conform to ASTM/API 5L standard and the ratio of yield strength to tensile strength shallnot exceed 0.85 for ASTM A 333, Gr. 6 Pipes and 0.90 for API 5L pipes.

For pipes containing welds, the fracture must occur outside of the weld. If there is a fracture in weld orHAZ, the tensile strength shall at least meet the requirements for tensile properties as per ASTM/API 5Lstandards.

Test specimen

The test specimen shall represent all pipes from the same lot.

Number of tests

For pipes NPS 2 and greater the following number of test shall be performed:

- Base material : one tension test

- Weld (if any) : one tension test

Test locations and orientations

For base material, test specimens shall be orientated transversally and if this orientation is not feasible, itshall be orientated longitudinally.

For welds, the test specimen shall be orientated transversally to the weld.

Test method

Testing shall be performed in accordance with ASTM A 370 standard rectangular plate type 1-1/2" wide(Fig. 4-A370) or standard round (Fig. 5 or Fig. 6-A370). Yield strength shall be determined either by the0.2 % offset or the 0.5 % extension under load (EUL) method.

Retest

If the tension test specimen from any lot fails to conform to the requirements of the particular gradeordered, retest shall be carried out for each pipe of the lot, which shall conform to the requirementsspecified in the ASTM standard and this specification. If the retest for any pipe fails to conform to therequirements, that pipe will be rejected.

5.2.2. Impact test

Requirements

Notch toughness properties Charpy V: the standard impact test temperature requirement as follows:


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Material Impact Test Temperature Energy Absorption Value

(Minimum)

Carbon Steel Material -20 Deg. C Individual 28J

Average 35JLow Temperature

Carbon Steel Material

-20 Deg. C Individual 28J

Average 35JMaterial Standard’ impact test

requirements temperature or -

45 Deg. C whichever is lower

Material Standard’s impact

test requirement

Test specimen

The test specimen shall be machined from material obtained as in paragraph Test specimen for Tension test(par. 5.2.1.).

Flattening of test specimens are not allowed.

Number of tests and orientation

Three test specimens shall constitute one test set.

For pipes NPS 2 and greater, the following number of tests shall be performed:

- Base material: 2 test sets, one set shall be orientated longitudinally and another one transversally.

- Weld: 1 test shall be orientated transversally.

- HAZ: 1 test shall be orientated transversally.

Test method

The notched bar impact test shall be made in accordance with ISO 148 - Charpy V - Notch.

If the wall thickness of the pipe or the coupon does not enable machining of full size specimens, the largestpossible size must be used but not less than (10 x 5 mm). The axis of the notch shall be orientated throughthe wall thickness of the pipe.

5.2.3. Flattening Test

For HFW pipes flattening test shall be carried out. Specimen shall be Flattened to ½ original OD withoutweld opening. Flattening shall continue to 1/3 of specified OD without cracks, other than in weld, andfurther continue until opposite walls of pipe meet and no lamination shall be observed on material on fullflattening. Dye penetrant testing may be used to positively confirm the presence of crack, break or opening.

5.2.4. Hardness Test

Hardness test shall be carried out as per the requirements of ASTM A 370. For acceptance, the Hardnessshall be below 248 HV10. Material with Hardness greater than 200 BHN (Max) shall be rejected. EachPipe, shall be subjected to Hardness Test.


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5.2.5. Micrographic Test

The Grain sizes shall be in the Range: 8 to 12 as per ASTM E 112. Each Pipe shall be subjected toMicrographic Test.

5.2.6. Retreatment

If the result of the mechanical tests does not conform to the requirements specified in par. 5.2, themanufacturer, with the acceptance of the purchaser and Owner/Owners representative, may retreat the eachpipes as applicable and repeat all the tests specified.

5.3. Chemical analysis

For each lot/item a new chemical analysis of the steel shall be done.

The chemical analysis shall conform to the requirements of the table 1 of this specification.

The carbon equivalent shall be computed by "check analysis": see par. 3.i.

C.E. £ 0.43.

5.4. UT testing

After the mechanical testing, all pipes must be controlled with UT over all the surface, longitudinal/Helicalseam weld and bevels.

l UT must be performed as per ASME code, section V, art. 23, SA - 388

l Acceptance criteria will be as follows :

q For base material :

u Criteria : ASME code, section VIII, division 1, UF-55 (angel probe will be used)

q For longitudinal seam welds:

u Criteria : ASME code, section VIII, division 1, Appendix 12

The following defects are unacceptable:

l Defects extending into the bevel provided the lamination is parallel to the surface and has a transversedimension exceeding 6.35 mm.

l Defects not parallel to the surface extending to the bevel

5.5. MPI testing

Magnetic particle testing shall be carried out on bevel surface of both ends, as per ASME Sec VIII Div.2Art-7.5.6.2.

6. INSPECTION AND CERTIFICATION

Inspection and certification shall be done by the Quality Control department of the pipe supplier and inpresence of the Control Authority representative and apply to:

q Identification of pipes with respect to mill certificates.


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q Visual and dimensional inspection.

q Sampling preparation for testing: stamping of specimens.

q Testing (destructive and non-destructive).

q Hydrostatic test.

q Marking: all accepted pipe lengths shall be identified by TPIA.

Final certification shall be as per EN 10204:3.2 and shall include the results of all performeddestructive, chemical check, hydrostatic test values and heat treatment data. This certificate shall besigned by the Control Authority.

7. INSPECTION BY CONTROL OPERATIONS: L.O.C.

Control and tests are carried out by the Piping Supplier under his responsibility and at his cost.

In order to ensure that material is in accordance with the applicable standard specification and with thisspecification, Supplier shall follow a program of inspection as set in the L.O.C. (List of Operations forControl).

It is the responsibility of the Quality Control department to prepare the L.O.C. sheet with their interventionpoints.

Each operation step, after checking of execution, shall be signed by the responsible Q.C. Inspector.

Notification to the TPIA/EPC Contractor for witnessing of testing operations, shall be done at least five (5)working days, by fax/E-mail, prior to the date scheduled to perform the test.

Each pipe in which injurious defects are found after delivery shall be rejected. The vendor shall be notified.In this case, the pipe shall be replaced immediately by the vendor. All costs involved, including wages andtravel expenses of the Control Authority and Engineer shall be borne by the EPC contractor.

1) All pipes furnished under this specification shall be clearly identified on the O.D. with the followinginformation marked with low stress die stamps or interrupted dot stamps as noted :

a) Manufacturer's name or trademark.

b) Heat code identity.

c) Pipe number: the pipe number shall be made up of six figures specified as follows:the item and his number specified in the purchase order.

d) The monogram of the Owner. This marking shall only be applied aftercomplete approval of the Certified Material Test Report.

2) In addition to the above, for NPS 2" and larger, it shall also include the following information :

Grade symbol: the grade symbol must designate the material of the pipe conforming to ASTM/APIcode.

3) Marking must be done prior to final inspection.


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8. CORROSION INSPECTION

The corrosion protection will be applied by the vendor after final inspection by the Control Authority.

The corrosion protection shall be line sealed oil at the outside of the pipe.

This product shall meet the following criteria:

l Guarantee a corrosion protection for a storage period in open air for at least 6 months.

l Shall be easily removable by wire brushing or by grinding.

l Shall not produce toxic vapour or smoke when heated by blow troches or during welding.

l The vendor shall deliver the necessary quantity of product (tri - chlore - ethylene) to remove this oil.

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TABLE 1

CHEMICAL COMPOSITION FOR WELDING END OF PIPES

Maximum limit of chemical elements which may be used in material under this standard.

% Maximum

C 0.230

Mn 1.60

Si 0.50

P 0.030

S 0.025

Nb 0.080

V 0.120

Mo 0.250

Nt 0.0150

Alternate alloy elements may be used but they shall be discussed with the user prior to delivery of the material. Thistable is not intended to represent the composition of any heat of steel, but merely to record the maximum permissibleamounts of one element. The combination of elements of any heat must conform to the carbon equivalent,subsection 3.i.

For each heat the manufacturer shall analyse the following elements: C, Mn, Si, P, S, Nb, V, Cr, Mo, Ni and Cu.

The intentional addition of elements other than those specified is not permitted unless agreed upon by the purchaser.

In any case, for unintentional additions, the following limitations shall be respected:

Cr ≤ 0.15 % Mo ≤ 0.05 % Cu ≤ 0.20 %

Ni ≤ 0.30 % Co ≤ 0.01 % Al ≤ 0.07 %

The content of N total (Nt) may be up to 0.0150 % and must be guaranteed by the manufacturer. If the manufacturercannot give any guaranty of N content, he shall analyse this element.

The total content for Nb + V will be limited to 0.150 %.

In grades X42 through X65 for each reduction of 0.01 % below the maximum carbon content, an increase of 0.05 %

manganese above the specified maximum is permissible, up to a maximum of 1.70 %.

Σ Σ Σ

PTS - LONG RADIUS BENDP.013828D 11077

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Page 1 of 12

VENDOR LOGO

IRCA LOGO



PARTICULAR TECHNICAL SPECIFICATION -

P

RERT

PTS – LONG RADIUS BEND



PTS-LONG RADIUS BENDP.013828D 11077

211


TABLE OF CONTENTS

1. SCOPE................................................................................................................................... 3

2. DEFINATION......................................................................................................................... 3

3. CODES, NORMS AND STANDARDS ....................................................................................... 3

4. MATERIAL............................................................................................................................. 4

5. MANUFACTURE..................................................................................................................... 5

6. BEND MANUFACTURING PROCEDURE QUALIFICATION...................................................... 7

7. INSPECTION & TESTS ....................................................................................................... 9

8. TEST CERTIFICATES....................................................................................................... 10

9. MARKING, PACKING AND SHIPMENT........................................................................ 10

10. DOCUMENTATION .......................................................................................................... 11

∑ ∑ ∑


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1. SCOPE

This specification covers the minimum requirements for manufacture and supply of long radius

bends made from Carbon Steel line pipes for use in onshore pipeline systems handling hydrocarbons in

gaseous.

2. DEFINATION

Client / Owner Shall mean GAIL (I) Limited

Manufacturer Means the Manufacturer of the long radius band.

EPC Contractor / Contractor The party which carries out all or part of Engineering,

Procurement, Construction, Pre-commissioning & Commissioning

of the project. It shall mean EPC Contractor in the present context.

Third Party Inspection

Agency (TPIA)

Means the Inspection Agency to be appointed by the EPC

contractor

Consultant / Owner

Representative

Shall means TRACTEBEL Engineering Pvt. Limited / The entity

of the purchaser or the company nominated by the purchaser to

design the natural gas transport or distribution system and to

specify the equipment

PTS Means the present <<Particular Technical Specification P.013828

M 11077 211> and its entire appendix, if any.


Reference has been made in this specification to the latest edition (edition enforce at the time of issue of

enquiry) of the following codes, standards and specifications:

a) ASME B 31.8 : Gas Transmission and Distribution Piping System

b) ASME B 16.25 : Butt welding Ends

c) API 5L : Specification for Line Pipe

d) ASTM A 370 : Standard Test Methods and Definitions for Mechanical Testing

Steel Products


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e) MSS-SP-75 : Specification for High Test Wrought Welding Fittings

f) ISO – 15590-1 : Petroleum and natural gas industries – Induction bends, fittings and

flanges for pipeline transportation systems – (Part 1 – Induction

Bends).

g) ASME B16.49 : Factory-made Wrought Steel, Butt welding Induction Bends for

Transportation and Distribution Systems.

h) Specification of Line : Refer tender specification elsewhere

Note:

In case of conflict between the requirement of above reference documents and this specification;

the requirements of this specification shall govern.

4. MATERIAL

4.1 Bends shall be fabricated from steel line pipe. The type of pipe to be used for fabrication of bends shall be

indicated in the Pipeline Design Basis. Pipe with positive wall thickness tolerances shall be used for

fabrication of bends.

4.2 Pipes used for bend fabrication shall be tested for chemical and mechanical properties in addition to review

of test certificate of line pipes.

4.3 Unless specified otherwise in the Work Order, the line pipes for fabrication of bends shall be procured by

EPC contractor.

4.4 Heat treatment shall be carried out for all finished bends in case it is established during bending procedure

qualification that heat treatment is required to meet the specification requirements. Heat treatment

procedure shall be such that the mechanical properties and steel microstructure of the finished bends

comply with the minimum requirements specified in the applicable line pipe specification referred under

clause 3.0. When TMCP and OLAC steels and micro alloyed steels are used, specific approval of the

proposed heat treatment shall be obtained before bending process is employed. The finished product shall

be evaluated for mechanical properties and micro structural stability.

4.5 Mechanical testing of test bends performed during the bend manufacturing procedure qualification as per

section 6.0 of this specification, shall ensure that all bends made according to the Client approved bend


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manufacturing procedure have the required mechanical properties and destructive testing of production

bend is not required. However, company reserves the right to require destructive testing whenever

production bending parameters or heat treatment parameters deviate from those established in the Company

approved bend manufacturing procedure.

5. MANUFACTURE

5.1 Material grade, bend size, bend radius and bend angle shall be as indicated in the PO. Unless specified

otherwise, the bending radius for bends shall be minimum six times the specified outside diameter.

5.2 Bends shall be manufactured by high frequency induction heating and forming method. Once the bending

operation has commenced no stoppage shall be permitted until the entire bend has been completed.

If bending temperature, bending rate, cooling medium volume or heat treatment temperature depart from

the company approved bend manufacturing procedure, then the pipe shall be discarded and another bend

shall be made in its place.

5.3 Hot Induction bends to be manufactured as per latest edition of standard ISO 15590-1 / ASME B16.49.

5.4 Except otherwise stated in this PTS and ISO-15590-1 / ASME B16.49 code; the testing, inspection methods

and acceptance criteria for induction bends shall be as required for pipe of the same steel grade and type.

Contractor may ask owner / owner’s representatives for relevant documents in due time.

5.5 When bending SAW Pipes, the longitudinal seam shall be located in the plane of minimum

deformation or neutral axis. Acceptable tolerance on location of the longitudinal weld seam shall be ± 50 .

5.6 All bends shall be provided with a tangent length at both ends. Tangent length shall be 500 mm or pipe

outside diameter whichever is more.

5.7 Unless otherwise specified differently in the PO, the bevels at the ends shall be as per the relevant pipe

specification.

5.8 Bends shall not have any circumferential joint.

5.9 No repair by welding is allowed on any part of the bends.

5.10 Bulges, dents and flat areas shall not appear within 100 mm front end of the bend. For the remaining part of

the bend these deviations from the original contour of the pipe are permitted provided these deviations do

not exceed 6.0 mm. The same shall not extend (in any direction) over a distance of more than 25 % of

normal diameter of the bend.

5.11 The excess weld material at the inside of the bend in case of bends made from SAW pipes, shall be

removed over a distance of 100 mm at both ends.


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5.12 TOLERANCES

The dimensions of bends shall be controlled to make sure that they are manufactured according to the

tolerances indicated below, in addition to the requirements of MSS-SP-75. However, the ends of finished

pipe bend shall meet the dimensional tolerances of the relevant pipe specification referred in clause 3.0.

5.13 Following tolerances shall be applicable for bend angle and bend radius:

Bend Angle : ± 0.5 0 from the specified angle

Bend Radius : ± 1 % of bending nominal radius (radius as indicated in Clause 5.1 above).

5.14 The manufacturer shall measure the wall thickness of the pipe before bending along both the

inside and outside radii of the bend between and including the start and stop points of the bend

arc angle, at intervals approximately equal to pipe diameter or 300 mm whichever is less. The

wall thickness shall be measured ultrasonically after bending at the same locations as

measured before bending. In addition, the wall thickness of the tangents shall also be

measured. These measurements shall be taken at four equally spaced locations around the pipe

circumference. The measured wall thickness shall be at least equal to:

Tmin = 0.95 (tactual - t)

Where

T actual

t

=

=

Actual wall thickness of pipe used for bending

0.35 mm for a wall thickness < 10 mm 0.5 mm for a wall thickness ≥ 10 mm5.15 Out of roundness tolerance on the body and ends of the bend shall be as follows:

Out of Roundness (mm)

Pipe Body OD > 6” - 5 mm max.

Pipe Ends OD > 6” - 3 mm max.

Note (1) : The inside diameter, based on circumferential measurement, over a

length of 300 mm or approximately equal to pipe diameter (whichever is less) from the end

shall comply with the tolerances specified in API Spec 5L/ISO 3183. Inside diameter is defined

as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter

and specified wall thickness respectively.

5.16 Off-Plane


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Off-Plane of bends shall not exceed (θ/ 90) X 10 mm, where θ is the bend angle in degree or

the tolerance limit specified in MSS-SP-75, whichever is less. The measurement shall be in

accordance with MSS-SP-75.

6. BEND MANUFACTURING PROCEDURE QUALIFICATION

6.1 Prior to start of production bending, Manufacturer shall demonstrate the suitability of the proposed

manufacturing procedures for producing pipe bends including the post-bending heat cycle, that

meet the requirements of this specification, by mechanically testing additional bend(s) (test

bends). The bending procedure shall be qualified in the presence of company representative.

6.2 Test bends shall be made by using the pipe specified in clause 3.0 of this specification.

One test bend is required per ‘heat-lot’ where a heat lot is deemed to include all bends of the same

diameter, wall thickness, mill heat number and bend forming parameters such as, bending

temperature, bending rate, cooling medium volume & heat treatment temperature (excluding bend

angle). The test bend shall be bent to an angle of 900.

6.3 Inspection and Testing of Bends

6.3.1 All finished test bends shall meet the requirement of dimensional tolerances, inspection and non-

destructive testing requirements specified in section 5.0 & 7.0 of this specification.

6.3.2 In addition all test bends shall be subjected to following mechanical testing to confirm that the

bends manufactured meet all mechanical property requirements of relevant line pipe specification.

Test procedure and acceptance criteria shall be in accordance with the relevant line pipe

specification. The test specimen shall be taken from the bent portion of the bend only.

a) Tensile test

One tensile test shall be conducted on the base material of finished test bend, to establish yield

strength, ultimate tensile strength and elongation. The specimen shall be taken longitudinal or

transverse to the axis as specified in the relevant pipe specification. In case of bends of 300 mm

(12”) NB and larger, the specimen shall be taken at inside radius and one at outside radius of bend.

b) All Weld Tensile Test

In case of bends fabricated from SAW Pipes, an all weld tensile test shall Be conducted to

establish yield strength, ultimate tensile strength and elongation of weld material on bend.

c) Guided Bend Test/ Reverse Bend Test


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Location

Impact Test

Temp.

Impact Energy Absorption ValueAvg. Value Individual Value

For Base

-20 °C 35 J 28 J0 °C 100 J 80 J

For Weld & HAZ Metal

I

-20 °C 35 J 28 J0 °C 40 J 32 J

For bends manufactured from SAW pipes one face and one root guided bend test shall be

performed. For bends manufactured from EW pipes, reverse bend test shall be carried out. Test

method and acceptance criteria shall be same as mentioned in applicable pipe specification.

d) Hardness Test

Hardness testing shall be performed “thru thickness” on a test ring removed from the middle of the

bend. Four specimens shall be prepared one from each quadrant. In case of bends fabricated from

SAW/EW pipes, one specimen shall have longitudinal weld seam in the middle. Hardness shall be

checked for base metal, weld metal and HAZ. In addition, hardness test shall be performed at spots

where dents, bulges or wrinkles have been formed on the bends. Hardness value shall be Max. 300

HV10 as per ISO 15590-1.

e) Fracture Toughness Test

Charpy - V notch test temperature shall be the same as specified in the relevant pipe

specifications. Three base material specimens shall be taken longitudinal or transverse to the

axis as specified in the relevant pipe specification. In case of bends fabricated from SAW and

EW pipes, three transverse weld material specimens shall be taken with weld in the middle. In

case of bends of 300 mm (12”) NB and larger, the base material specimens shall be taken at

the outside radius of the bend.

The Charpy V-notch impact testing of LR bends (for API 5L material) as indicated shall be

carried out as following:

Should test bends fail to comply with the above requirements, the bend

manufacturing procedure shall be disqualified. The manufacturer shall revise the manufacturing

procedure and re- qualify the same at his own cost and time. Upon completion of the successful

procedure qualification, manufacturer shall provide a written bending procedure for each test

bend. The submitted procedure shall indicate in addition to the details as per clause8.0, tolerances

on various controlling parameters.


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7. INSPECTION & TESTS

7.1 The manufacture shall perform all inspection and tests as per the requirements of this specification

and MSS-SP-75 prior to shipment, at his works. Such inspection and tests shall be as a minimum,

but not limited to the following:

a) Verify that the unfinished product arriving at Manufacture’s shop is in full

compliance with the pipe specification as referred in clause 3.0 of this specification.

b) Visual inspection

c) Dimensional and tolerances check as per MSS-SP-75 and requirements of Section 5.0 of

this specification.

d) Check heat treatment, if carried out, as required and maintain its records.

e) Temperature against time recorder charts for each induction heating.

f) The non-destructive inspection on the finished bend shall be carried out as given below:

- All seam welds of bends manufactured from SAW pipes shall be 100% radiographed

tested. The acceptance criteria shall be relevant pipe specification.

- The full circumference of both ends of each bend after bevelling shall be ultrasonically

tested for laminations over a length of 25 mm and acceptance limits shall be as per pipe

specification as per relevant pipe specification.

- The finished bends shall be magnetic particle inspected on the outside and inside radii to

include the area encompassed 30 degree either side of the line passing through the plane

of bend. Acceptance criteria shall be as per ASME Sec. VIII Appendix 6.

g) A check shall be performed on each bend by passing a gauging pig consisting of two discs

having a diameter equal to 95% of the nominal internal diameter of the pipe, connected rigidly

together at a distance equal to 500 mm. Details of the gauging pig, including its dimensions

shall be approved by company.

7.2 TPIA reserves the right to perform stage wise inspection and witness tests on all bends as indicated in

Clause 6.1 at Manufacturer’s works, prior to shipment.

Manufacturer shall give reasonable notice of time and shall provide without charge reasonable

access and facilities required for inspection, to the TPIA. Inspection and tests performed or


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witnessed by TPIA shall in no way relieve the Manufacturer’s obligation to perform the required

inspection and tests. Under no circumstances any action of the TPIA shall relieve the

Manufacturer of this responsibility for the material and quality of bends.

8. TEST CERTIFICATES

The Manufacturer shall submit the following certificates:

a) Test certificate of chemical analysis, Mechanical tests, heat treatment, NDT,

dimensional inspection and hydrotest carried out on pipe used for fabrication of bend.

These test certificates are not required when pipe is supplied as free issue by company.

b) Certificates of non-destructive test/ examination carried out on bends. Records of

heat treatment, if carried out for bends.

c) Certified reports of dimensional tolerance of bends.

d) Certificates of all other tests as required in this specification.

The Certificate shall be valid only when signed by Company’s Inspector. Only those bends

which have been certified by Company’s Inspector shall be dispatched from Manufacturer’s

works.

9. MARKING, PACKING AND SHIPMENT

9.1 All bends shall be marked as per MSS-SP-75.

9.2 All loose and foreign material like rust, grease, etc. shall be removed from inside and outside of the

bends.

9.3 One coat of antirust paint shall be applied on the bends for protection during transit and storage. Type of

paint shall be as agreed upon with the company.

9.4 Both ends of all bends shall be suitably protected to avoid any damage during transit by means of

metallic or high impact plastic bevel protectors.

9.5 Package shall be marked legibly with suitable marking ink to indicate the following:

a) Order Number

b) Package Number


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c) Manufacturer’s Name

d) Size (Inches) and Wall thickness (mm)

e) Radius of bend (mm)

10. DOCUMENTATION

Documentation to be submitted by Manufacturer to Company is summarized below.Number of copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACTdocument.

10.1 All documents shall be in English language

10.2 At the time of bidding, bidder shall submit the following documents:

a) Reference list of previous supplies of bends of similar specifications.

b) Brief description of manufacturing including heat treatment and quality control facilities

of the Manufacturer’s Works.

10.3 Within three weeks o f placement of order, the manufacturer/ contractor shall submit bend

manufacturing procedure including manufacturing, inspection, testing procedures, quality control

manual and quality plans.

10.4 The Bend Manufacturing Procedure shall detail the following, as a minimum:

a) Sequence of Operation

b) Induction forming process including bending temperature, temperature Control,

bending Rate, cooling rate and cooling procedure.

c) Temperature measurement and calibration.

d) Post bend heat treatment procedure including temperature and time.

e) Dimensional control procedure.

f) Pipe material used for bend manufacture

g) NDT procedures


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h) Quality Control and Quality Plans

10.5 Upon successful completion of the bend manufacturing procedure qualification as per section 6.0 of

this specification, Manufacturer shall submit the qualified procedure to company for approval.

Regular production of bends shall commence only after the bend manufacturing procedure has been

qualified and approved by company.

10.6 Once the approval has been given by Company any change in material and method of manufacture

and quality control shall be notified to company whose approval in writing of all such changes shall

be obtained before the bends are manufactured.

10.7 Within 30 days from the approval date, Manufacturer shall submit to Company the approved drawings,

documents and specifications as listed in clause 8.3 above.

10.8 Prior to shipment, the Manufacturer shall submit test certificates as listed in section 8 .0 of this

specification.

∑ ∑ ∑

PTS - FITTINGS & FLANGESP.013828D 11077

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Page 1 of 26

VENDOR LOGO

IRCA LOGO



PTS - FITTINGS & FLANGES

(Up to 12” Size)




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TABLE OF CONTENTS

1. GENERAL .............................................................................................................................. 3

2. DESIGN AND CONSTRUCTION ............................................................................................. 5

3. MATERIALS ........................................................................................................................ 10

4. FABRICATION AND TEST ................................................................................................... 11

5. UPGRADING FROM 3.1 TO 3.2 CERTIFICATE..................................................................... 14

6. INSPECTION....................................................................................................................... 20

7. CORROSION PROTECTION................................................................................................. 21

S S S


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1. GENERAL

This specification describes the requirements of fittings and flanges to be installed on Barmer Pali Pipeline

and particularly in the despatch stations, intermediate pigging stations and tap off, receiving stations and

sectionalizing valve stations.

This specification also describes the examinations and upgrading tests to be performed for obtaining a 3.2

certificate on the standard new fittings and flanges or taken out of stock with a 3.1 certificate.

The fittings have to be delivered in accordance to the particular specification:

Codes, Norms and standards (latest revision); but not limited to:

ANSI B16.5 Pipe flanges and flanged fittings

ANSI B16.9 Factory - made wrought steel butt welding fittings.

ANSI B 16.11 Forged steel fittings

ANSI B16.28 Wrought steel butt welding short radius elbows and returns

ASME B31.3 ASME code for process piping.

ASME B31.4

ASME B31.8 Gas transmission and distribution piping systems.

ANSI B36.10 Welded and seamless wrought steel pipe

ASTM A 105/

A 105 M

Forging, carbon steel, for piping components.

ASTM A 203 Pressure vessel plates, alloy steel, nickels

ASTM A 234/

A 234 M

Piping, fittings of wrought carbon steel and alloy steel for moderate and elevated

temperatures

ASTM A 333 Seamless and welded steel pipe for low temperature

ASTM A 350/

A 350 M

Forging, carbon and low alloy steel, requiring notch toughness testing for piping

components.

ASTM A 370 Mechanical testing of steel products.

ASTM A 420/

A 420 M

Piping fittings of wrought carbon steel and alloy steel for low temperature service.

ASTM E 112 Standard methods for determining the average grain size.


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MSS SP 25 Standard marking system for valves, fittings, flanges and unions.

MSS SP 55 Quality standard for steel castings for valves, flanges and fittings and other piping

components (visual method).

MSS SP 75 Specification for high test wrought butt welding fittings.

ASME Boiler and Pressure Vessel code.

DIN 2413 Design of Steel Pressure Pipes

EN 10204 Type of Inspection documents

ISO 148 Metallic Material - Charpy Pendulum impact test

ISO 9001 Quality management standard

The present specification can confirm, complete or alter certain characteristics or tolerances of existing laws

or specifications.

In his offer, the manufacturer or vendor shall specify all proposed modifications or alternatives to the

present specification. In all cases, each modification has to be submitted to the EPC contractor and the

Client/Consultant. The complete upgrading cycle shall be supervised by a EPC contractor. All

consequences after eventual order for non respect of this obligation are at the manufacturer's charge and

responsibility.


Before the order is placed, a technical audit will take place with EPC contractor/ Client.

The manufacturer's specification of the steel, the manufacturing procedure itself and the laboratories in

which testing takes place, shall be approved and registered by the EPC contractor. Valid approval

certificates must be available.

The EPC contractor shall verify the control equipment of the manufacturer, its calibration and the points at

which it is located. If during the control of the fittings certain problems arise the EPC contractor agent may

demand supplementary tests at the cost of the manufacturer.

At all times while work on the contract of the Client is being performed, the inspector representing the

Client shall have free entry to all parts of the manufacturer's facilities and those of all subcontractors, who

are involved in the manufacturing of the fittings. All reasonable facilities shall be afforded to the inspector

to satisfy him that the product is being furnished in accordance with these specifications. All tests and

inspections called for by these specifications will be made in the manufacturer's plant prior to shipment and

at the manufacturer's expense, unless otherwise, and shall be conducted as not to interfere unnecessarily

with the operations of the manufacturer's plant. The manufacturer shall notify the Client prior to completion

or shipment of all fittings requiring such inspection.


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Eventual interpretations and deviations to this specification by the Manufacturer shall be requested by

writing in his offer with detailed justification and approved by the Client/Consultant and the Authorised

EPC contractor before eventual order to the Manufacturer. The latter is responsible and shall indemnify the

Client/Consultant for any damage resulting from the non-respect of this obligation.

An approval of documents can never be considered as an acceptance of deviations or relaxations to

requirements. A deviation is only possible after specific request to the Client.

1.1. Glossary

Client Shall mean GAIL (I) Limited

Manufacturer means the Manufacturer of the Fittings &Flanges as well as its sub-contractor(s)

PTS means the present «Particular Technical Specification P.013828M 11077 212 » and all its appendices, if any.

EPC Contractor/Contractor party which carries out all or part of Engineering, Procurement,Construction, Pre-commissioning & Commissioning of the project.It shall mean EPC Contractor in the present context.

Third PartyInspection Agency (TPIA) means the Inspection Agency to be appointed by the EPC contractor

Consultant /Owner Shall means TRACTEBEL Engineering Pvt. Limited /

Representative The entity of the Client or the company nominated by the Client to

design the natural gas transport or distribution system and to specify

the equipment


2.1. The pressure temperature ratings for tee, weldolets, elbows and flanges shall be calculated respectively in

accordance with ANSI B31.8, DIN2413 and ANSI B16.5. For all other types of fittings (caps, reducers,

nipple) ASME section VIII shall apply.

The standard dimension shall be in accordance

l Flanges such as weld neck flanges and blind flanges shall conform to the requirements as follows :

- ASME B16.5 upto sizes DN 600 mm (24") excluding DN 550 mm (22"),

- MSS-SP-44 for sizes DN 550 mm (22").

l With ANSI B16.9 for the tees, reducers and elbows (except for short radius elbows which should be in

accordance with ANSI B16.28)

l With ANSI B 16.9 for the caps,

l With ANSI B 36.10 for the nipples,

l And with ANSI B16.5 / MSS SP 44 for the flanges.


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2.2. The temperature range as follows:

· For above ground Services (CS) : -20°C to +65°C

· For above ground Services (LTCS) : -45°C to +65°C

· For Underground Services : -20°C to +60°C

The Design pressure is 98 barg.

2.3. The wall thickness shall meet the following requirements:

2.3.1. The maximum allowable stress in the base material and in the weld shall be equal to fifty per cent (50%) of

the minimum yield strength guaranteed by the specification of the steel used.

2.3.2. The minimum wall thickness must be greater than the following:

a. Thickness calculated in line with requirements given in ASME B 16.9 Para 2.2

b. Nominal Thickness of pipe

Thickness calculation is to be submitted to Owner/Owner’s Representative for prior approval before

manufacturing.

2.3.3. If the fitting has yield strength lower than the yield strength of the pipe to which it is intended to be welded,

the wall thickness in each zone of the fitting is at least equal to the largest value "tr" of either.

l The specified pipe wall thickness times the ratio of the minimum yield strength guaranteed by the

standard of the steel of the pipe and the minimum yield strength guaranteed by the standard of the steel

of the fitting;

l The absolute minimum thickness required by the applicable code(s).

2.3.4. The specified pipe wall thickness and grade (with reference to the equivalent grade in ASTM spec. or API

5L spec.) with which the fitting and flange is intended to be used is specified in the piping material

specification.

Fittings such as tees, elbows, reducers, etc. shall be either welded or seamless type. All welded fittings shallbe subjected to heat treatment. All fittings (except weldolets) shall comply with

The requirements of MSS-SP-75. Fittings such as weldolets etc. shall be manufactured in accordance withMSS-SP-97.

Welded pipes used for fittings shall be LSAW type only.


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2.3.5. The thickness at the welding end shall not exceed 1.5 times the nominal wall thickness of the pipe to be

matched.

2.3.6. All the above requirements also apply to the welding ends of the flanges.

2.4. The manufacturer shall submit for approval to the EPC contractor and to the Client the dimensional

drawings, calculations, and the material part lists for all the types of fittings and flanges. All the documents

must be identified with the Client's order number.

2.5. The design shall take into consideration performance requirements prescribed in paragraph 2.6.

The design of tees, reducers or elbows must be established, by proof testing, in accordance with par. 2.7.

The design of the other fittings must be established by mathematical analysis according to ASME code.

2.6. All fittings under this specification shall be designed to withstand a field hydrostatic test pressure with non

corrosive water, after installation, during 24 hours at a following pressure level:

Minimum: P = 1.5 MOP

Where:

P = hydrostatic test pressure, bar

MOP = maximum operating pressure = 91barg.

The pressure level will however not exceed 1.9 MOP for the fittings and 1.5 times the 38°C pressure

rating for the flanges.

2.7. Design Proof Test

This applies to fitting only and not to flanges.

2.7.1. In addition to the requirements of par. 2.3.1 to 2.3.4 proof tests shall be made as evidence of the adequacy

to the design references. Records of design or successful proof tests shall be available at the facility for

inspection by the Client and copy shall be added to the Certified Material Test Report (CMTR, par. 6.3.).

2.7.2. Unless otherwise agreed upon between manufacturer and Client, the only required proof test is a bursting

strength test.

2.7.2.1. Prototype fittings, representatives of production, selected for test shall be identified as to material, grade,

and lot, including heat treatment. They shall be inspected for dimensional compliance to this standard.

2.7.2.2. Straight seamless or welded pipe sections, whose calculated bursting strength is at least as great as that

calculated for the fittings, shall be welded to each end of the fitting to be tested. Any internal misalignment

greater than 0.06 inch (1.6 mm) shall be reduced by taper boring at a slope not over 1:3. Length of pipe

sections for closures shall be at least twice the pipe O.D. Shorter lengths may be used as follows:

l The assembly must withstand at least 110 % of the pressure computed in 2.7.2.3.

l Minimum length of pipe shall be one pipe O.D. for sizes NPS 8" and smaller.


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Test fluid shall be water or other liquid used for hydrostatic testing.

2.7.2.3. Hydrostatic pressure shall be applied until the fitting ruptures. The actual test pressure prior to rupture must

at least be equal to the adjusted proof test pressure defined as follows:

P (adj.) = P xS act

s( .)

where

P (adj.) = the adjusted proof test pressure, bar

P = the computed proof test pressure at burst of any part of the assembly, bar

S = minimum specified tensile strength of the pipe for which the fitting is intended to be

used, N/mm2

S (act.) = the actual tensile strength of the material of the test fitting (determined on specimen

representative of the test fitting), N/mm2

The computed proof test pressure shall be determined as follows:

which refers to the pipe which the fitting's marking identifies and, where

P =20S t

D.

where,

P = Computed bursting pressure of the pipe, bar

S = Minimum specified tensile strength of the pipe, N/mm2

t = Nominal pipe wall thickness, mm

D = Specified outside diameter of pipe, mm

2.7.2.4. As an alternate, if the pipe ruptures, or if sufficient pressure to rupture any part of the assembly cannot be

attained, the test pressure is acceptable if a final test pressure is at least 105 % of the adjusted proof test

pressure.

2.7.3. A successful proof test on a prototype fitting, selected as required in subsection 2.7.2.1., may be used to

qualify other fittings to the extent described herein.

2.7.3.1. One test fitting may be used to qualify similar designs which shall not be smaller than one-half nor larger

than two times the size of the test fitting.

2.7.3.2. The test on a non-reducing fitting qualifies reducing fittings of the same pattern.

2.7.3.3. The untested fitting must have a t/D ratio neither less than one-half nor more than three times the t/D of the

test fitting.


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2.7.3.4. The pressure retaining capacity of a fitting, made of various grades of steel, will be essentially directly

proportional to the tensile properties of the various grades. Hence, it is necessary to test a prototype in only

a single grade to prove the geometric design of the fitting.

2.7.3.5. A test on a prototype elbow qualifies elbows having longer radii than the test fitting providing they qualify

under 2.7.3.1 and 2.7.3.3.

2.7.3.6. A change in design from seamless fitting to fitting containing (a) seam weld(s) require(s) an appropriate

prototype test. A change of location of the seam weld requires a separate prototype test. Any deviation

must be submitted for approval to the EPC contractor.

2.7.4. If the manufacturer cannot give the certificate of prototype bursting test, the design of fittings shall be

verified as follows. A prototype must withstand during 24 hours 1.4 times the maximum operating pressure

(M.O.P). The prototype is considered to be agreed upon if the deformations measured during the test at 1.4

X M.O.P. shows that the stress does not exceed 70 % of the minimum guaranteed yield strength of the

fitting.

The certificate of this prototype qualifies in the same limits than par. 2.7.3.

2.8. Fitting dimensions

One of the principles of this standard is the maintenance of a fixed position for the welding ends with

reference to the centreline of the fittings or the overall dimensions, as the case may be.

Dimensional standards will be in accordance with §2.1.

2.9. Fitting and Flanges Tolerances

2.9.1. Tolerances for welding ends, out-of-roundness at the welding ends and inside diameter at the bevel are

shown hereafter. Other tolerances wall thickness are as per corresponding codes: ANSI B16.9 standard and

for short radius elbows ANSI B16.28 standard.

2.9.2. Welding ends

The welding end and bevel shall be in accordance with Figure 1 for wall thickness up to 20.0 mm ; for

thicker walls, refer to Figure 2. The welding end land of the fitting & flanges shall be machined flat and

shall not vary from the plane by more than 0.03 in (0.8 mm) at any point. If a fitting & flange has a

thickness unequal to the pipe with which it is intended to be used, the welding end preparation at the joint

has to conform with Figure 3.

2.9.3. Out-of-roundness at the welding ends

The out-of-roundness, defined as the difference between the maximum and the minimum inside diameter at

the welding ends shall not exceed 1 % of the specified inside diameter for sizes NPS 4 and smaller. Fittings

& flanges NPS 4 and larger shall be machined true round.

2.10. Inside Diameter


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The inside diameter at any place at end (bevel) shall be the following:

NPS Tolerance of inside Ø at end (mm)

1/2" – 24” + 1.6 - 0.4

(1) The tolerance refers to variation from nominal I.D. calculating by (O.D. nom. - 2 t nom.).

(2) Flange Bore to match with I.D. of the pipe.

3. MATERIALS

3.1. The steel used in the manufacture of fittings & flanges shall be selected by the manufacturer and submitted

for approval to the Client and the EPC contractor at the time of the offer. The manufacturer shall fill in the

data sheet.

3.2. The chemical composition of the steel meets the requirements of Table 1.

3.3. The steel used has tensile properties conforming to the requirements prescribed in the ASTM standards.

3.4. The ratio of yield strength to tensile strength shall not exceed 0.90.

3.5. The material for fittings shall consist of blooms, billets, slabs, forging quality bar, plate, seamless or fusion

welded tubular products with filler metal added.

3.6. The steel shall be fully killed, fine grain practice.

3.7. The steel used shall be suitable for field welding to other fittings, pipes, flanges, or valves manufactured

under ASTM specifications A333, A350, A352, A381, A420, A694, A707 or API standards specifications

5L, 6D, 605 or MSS standards SP-44, SP-72, SP-75, EN 10208-2 in line with Piping Specification 6C1

attached with the tender document.

3.8. If preheating of the material is required to ensure proper weldability under normal field conditions, the

manufacturer shall state so in the offer, specifying preheat requirements and if accepted by the Client this

shall be permanently indicated on the fitting & flanges.

3.9. The Manufacturer must deliver a certificate EN 10204 (3.1 for upgrade fitting & flange; 3.2 if new), stating

the quality, the mechanical properties (yield strength, tensile strength, percent elongation, impact test,

chemical analysis, the process of manufacture and the marking (for example the heat number of material) of

the steel.


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3.10. Chemical Composition

3.10.1. For each heat the manufacturer shall check a chemical analysis of the steel (see Table 1).

3.10.2. Check analysis

Carbon equivalent shall be computed by the following equation:

C.E. = C +Mn6

+5

VMoCr +++

Ni Cu+15

And shall not exceed 0.43


For all forging materials, the specimen shall be taken from the integral part of the forging.

The par.4.1 to 4.2 are only applicable on welded fittings.

4.1. Welding Fabrication

4.1.1. All welds and repair welds shall be performed according to written procedures. The welding procedure

must be submitted for approval to the EPC contractor before any fabrication.

Only qualified & approved welders and welding operators shall be used in production.

4.1.2. The joints shall be furnished in accordance with the requirements of Section VIII of ASME Boiler and

Pressure Vessel Code.

4.1.3. Machine welding shall be done by an electric process, preferably by submerged arc.

4.1.4. All butt welds shall have full penetration. Submerged arc machine welding shall be done with at least one

pass from the inside, except when accessibility makes this impossible, then a manual or machine root bead

may be employed provided that a visual inspection of the root bead is possible. Backing rings shall be not

used.

4.1.5. Repair, chipping or grinding of welds shall be done in such a manner as not to gouge, groove, or reduce the

original metal thickness by more than 6 1/2 % of nominal specified wall.

4.1.6. Except for bar in the tees, fillet welds shall not be permitted.

4.1.7. Welded-on braces, if used, should be removed before heat treatment and the weld spot shall be repaired and

ground flush and smooth. However, when braces are required for heat treatment, they shall be cut out and

the surface shall be ground flush and smooth after heat treatment. Except for bar in the tees, welding shall

not be permitted after heat treatment. The ground areas shall be inspected by magnetic particle or liquid

penetrant testing.

4.2. Welding Procedures

4.2.1. All welds, repair welds and repair by welding shall be performed according to written procedures. These

welding procedures shall be qualified according to the requirements of the ASME Boiler and Pressure

Vessel Code, Section IX.


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The welding procedure tests are required on material which is on the high side of the chemistry

specification.

The manufacturer shall maintain a weld record of the procedure and performance test results. The test

coupons shall be submitted to the same fabrication and heat treatment as the actual fittings.

The welding procedure qualification must include an impact test set in the weld and in the HAZ with

requirements of paragraph 5.1.2 and a macrographic examination described in paragraph 4.2.2. These tests

shall be performed after eventual final heat treatment.

4.2.2. Macrographic examination: the etched surface of the macro test specimen viewed macroscopically must

display the image of a well performed welded joint with sufficient penetration, free from linear defects and

important inclusions. In case of doubt, the etched surface must be examined microscopically and additional

macroscopical examinations of other areas may be required.

The macrographic examination will include hardness measurements in the weld and the HAZ. The hardness

will not exceed the values measured on the parent metal by more than 80 points for the welds and 100 point

for HAZ, with an absolute maximum of 350HV10.

The acceptance of inclusions can be decided upon with the NDE of the welded plates (see paragraph 5.3).

4.2.3. Transverse guided bend test

4.2.3.1. Test method

Transverse weld test specimens shall be subjected to face and root guided bend tests. The specimens shall

be approximately 1.5 in (38 mm) wide, at least 6 in (152 mm) long with the weld at the centre, and shall be

machined in accordance with Figure 4. The face bend specimen shall be bent with the inside surface of the

pipe against the plunger, and the root bend specimen with the outside surface against the plunger. The

dimensions of the plunger for the bending jig shall be in accordance with Figure 5 and the other dimensions

shall be substantially as shown in Figure 5.

The manufacturer shall use a "jig" based on this dimension or a smaller dimension at this option.

4.2.3.2. Test specimen

The weld bend test specimens, as described hereabove shall be cut from the coupon. The specimens may be

taken from a fitting or from sample plates as described in par. 4.2.3.1.

4.2.3.3. Acceptance criteria

The bend test shall be acceptable if no cracks or other defects exceeding 0.12 in (3.2 mm) in any direction

are present in the weld metal or between the weld metal and the fitting metal after the bending. Cracks

which originate along the edges of the specimen during testing and which are less than 0.25 in (6.4 mm)

measured in any direction, shall not be considered unless obvious defects are observed.


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4.2.3.4. Retest

If either test fails to conform to specified requirements, the manufacturer may elect to make retests on two

additional specimens from the same lot, each of which shall conform to the requirements specified

hereabove. If any of these specimens fail to conform to the requirements, the welding procedure

qualification test is not accepted.

(*) A lot consists of all fittings/flanges from one heat of steel with same initial wall thickness, from the

same furnace charge for final normalizing heat treatment, from the same shape and the same main pipe

dimension.

4.2.4. Number of tests

The nature and number of tests are specified in the Table below and only one retest is allowed.

Specification test Number

Non destructive test par. 5.3. par. 5.3

X-ray and U.S. testing par. 5.3 par.5.3.

Destructive test All specimens shall be taken transverse to the weld

Tensile par. 5.1.1. 2

Bend test Face par. 4.2.3. 2

Root par. 4.2.3 2

Impact Weld par. 5.1.2. 1 set of 3 specimens

HAZ par. 5.1.2. 1 set of 3 specimens

Macrographic examination par. 4.2.2 1

4.3. Normalising Heat Treatment

Start & stop temperature chart shall be signed by TPIA, also power failure log shall be maintained.

4.3.1. After forming and welding, all fittings & flanges shall be heat treated by normalising. Normalising shall be

carried out in such a way that the base material acquires a fine grained perlitic structure. If the

manufacturer can give proof by qualified manufacturing procedure that after forming, the steel of the fitting

& flanges has a homogeneous fine grained perlitic structure, he can ask for a derogation supported by

technical file to the Client and to the EPC contractor.

The normalizing procedure requires the approval of the EPC contractor. Good care shall be taken to avoid

direct contact of the flames with the material to be heated.

During the normalizing period, the temperature of the heat treatment lot shall be automatically recorded by

a sufficient number of thermocouples attached to the material surface. The thermocouples shall be

adequately protected against the influence of heat radiation. Temperature variations shall be within ± 20°C.


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The manufacturer shall furnish time temperature charts of each heat treatment lot. The fittings & flanges

belonging to each treatment lot shall be specified on the charts. Temperature measurements by other means

are permitted only if approved by the EPC contractor.

4.3.2. The fine grained perlitic structure of the steel shall be verified by at least one micrographic examination per

lot (definition in §4.2.4), according to ASTM E 112. The grain size shall be in the range of 8 to 12.

4.3.3. The manufacturer shall include in the CMTR data of this treatment.

5. UPGRADING FROM 3.1 TO 3.2 CERTIFICATE

5.1. Mechanical Tests

The following mechanical tests shall be performed by the vendor under the supervision of the EPC

contractor and the certificates shall be added to the CMTR.

Test specimens may only be cut after a marking transfer by the Authorised EPC contractor. All the tests

shall be performed after final heat treatment.

Certification requirements to comply with EN 10204 – 3.2 certificates shall issued by TPIA

5.1.1. Tension test

5.1.1.1. Requirements

The material shall be in conformance with the ASTM standards and the ratio of yield stress to tensile stress

shall not exceed 0.90.

For fittings containing welds, the fracture must be outside of the weld. If there is a fracture in weld or HAZ,

the tensile strength shall at least meet the requirements for tensile properties as per ASTM standards.


The test specimen shall represent all forgings from the same lot. Test specimens shall be taken from the

fitting after final heat treatment or from a piece of pipe or plate of the same nominal thickness, same heat of

steel from which the fitting is made and which has been heat treated in a lot with any of the fitting(s) it

represents. For welded fittings, this coupon (piece of pipe or plate) shall contain a weld in prolongation of

the weld of the fitting.

5.1.1.3. Number of tests

For fittings NPS 2 and greater the following number of test shall be performed:

l Base material : one tension test

l Weld : one tension test

5.1.1.4. Test locations and orientations


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For welds, the test specimen shall be orientated transversally to the weld. For base material, test specimens

shall be orientated transversally and if this orientation is not feasible, it shall be orientated longitudinally.

For flanges, the test location shall be in accordance with ASTM A350§6.1.3.


Testing shall be performed in accordance with ASTM A 370 standard rectangular plate type 1-1/2" wide

(Fig. 4-A370) or standard round (Fig. 5 or Fig. 6-A370). Yield strength shall be determined either by the

0.2 % offset or the 0.5 % extension under load (EUL) method.

5.1.1.6. Retest

If the tension test specimen from any lot fails to conform to the requirements of the particular grade

ordered, the manufacturer may elect to make retests on two additional pieces from the same lot. If one or

both of the retests fail to conform to the requirements, the whole lot of that specimen will be rejected.

5.1.2. Impact test


For product, the Charpy V- Notch test shall be conducted as per following requirements:

Material Impact Test Temperature Energy Absorption Value(Minimum)

Carbon Steel Material -20 Deg. C Individual 28J

Average 35J

Low Temperature

Carbon Steel Material

-20 Deg. C Individual 28J

Average 35J

Material Standard’ impact testrequirements temperature or

- 45 Deg. C whichever is lower

Material Standard’s impact testrequirement


The test specimen shall be machined from material obtained as in paragraph Test specimen for Tension test

(par. 5.1.1.2.).

Flattening of test specimens are not allowed.

5.1.2.3. Number of tests and orientation

Three test specimens shall constitute one test set.

For fittings NPS 2 and greater, the following number of tests shall be performed :

l Base material : 2 test sets, one set shall be orientated longitudinally and another one transversally.

l Weld : 1 test shall be orientated transversally.


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l HAZ : 1 test shall be orientated transversally.


The notched bar impact test shall be made in accordance with ISO 148 - Charpy V - Notch.

If the wall thickness of the fitting or the coupon does not enable machining of full size specimens, the

largest possible size must be used but not less than (10 x 5 mm). The axis of the notch shall be orientated

through the wall thickness of the fitting.

5.1.3. Flattening test

This is not applicable to the flanges.


Flatten to 1/3 original O.D. without cracks or breaks in the fitting, continue flattening until meeting opposite

walls of the fitting.

No evidence of lamination of burnt metal may develop during entire test.


The test specimen represents all the fittings from the same heat of steel of the same shape and of the same

main pipe dimension of the fittings.

5.1.3.3. Number of tests

For fittings size lower than 2” one flattening test shall be made per test specimen.

5.1.4. Retreatment

If the result of the mechanical tests does not conform to the requirements specified in par. 5.1.3.1., the

manufacturer, with the acceptance of the Client and the EPC contractor, may reheat treat the fittings as

applicable and repeat all the tests specified.

5.2. Chemical Analysis

For each lot/item a new chemical analysis of the steel shall be done.

The chemical analysis shall conform to the ASTM requirements specified in the specification.

The carbon equivalent shall be computed by "check analysis": see par. 3.10.2 with C.E. £ 0.43.

The reports shall be added to the CMTR reports and approved by the EPC contractor.

5.3. Non Destructive Examinations (NDE)

The following mechanical tests shall be performed by the vendor under the supervision of the EPC

contractor and the certificates shall be added to the CMTR.

5.3.1. Radiography


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All butt and repair welds shall be 100% radiographed in accordance with ASME section V - non destructive

examination - article 2 - using fine grain film and lead screens. Acceptance criteria shall be as be ASME B

31.4 or ASME B 31.8 as applicable and API 1104. Radiography shall be performed after the final heat

treatment.

5.3.2. U.S., Magnetic, Visual and Dimensional examination

5.3.2.1. Non destructive examinations

In the presence of the TPIA, the manufacturer shall perform the following non destructive examinations on

the fittings after the mechanical tests and according to an inspection procedure to be submitted for approval.

l For fitting with wall thickness larger than or equal to 6 mm, ultrasonic inspection on the whole surface

(with angle probe and straight probe) to the maximum extent possible.

l All finished wrought weld ends shall be 100% tested for lamination type defects by ultrasonic test. Any

lamination larger then 6.35 mm shall not be acceptable.

l When elbows of size > DN 300 mm (12") are manufactured, the first elbow of each radius, diameter

and wall thickness shall be ultrasonically checked for sufficient wall thickness in areas where a

minimum wall thickness is to be expected. This shall be followed by random inspection of one out of

every three elbows of the same radius, diameter and wall thickness.

l Magnetic Particle or Liquid Penetrant Examination shall be performed on cold formed.

l Butt welding tees with extruded outlets as per applicable material standard.

l Welds, which 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 U and

Appendix VI respectively.

l Magnetic particle inspection on the whole external surface and the accessible internal surface.

5.3.2.2. Ultrasonic inspection

Ultrasonic inspection of all welds and 25 mm of base material at each side of the weld shall be done.

5.3.2.3. Visual examination

All fitting & flanges shall be visually examined.

5.3.2.4. Test after machining

After machining, all the finished bevels shall be submitted to the following tests:

l Magnetic particle or liquid penetrant

l For fitting and flanges with wall thickness larger than or equal to 6 mm, ultrasonic inspection on 25

mm of base material.


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5.3.2.5. Dimensional examination

l For fittings up to NPS 6, the TPIA shall choose 10 % with a minimum of one piece per item of the

order and these pieces shall be submitted to a dimensional examination.

l For fittings larger than NPS 6, all pieces shall be submitted to a dimensional examination

l All flanges shall be submitted to a dimensional examination.

5.3.3. Acceptance criteria of the different NDE

5.3.3.1. Visual examination


l Undercuts exceeding 1 mm in depth and 25 mm in length.

l Undercuts of the outside weld which overlap undercuts of the inside weld.

l Lack of penetration.

l Continuous occurrence of under-cutting.

5.3.3.2. Magnetic particle inspection

Magnetic particle inspection on the external surface. ASME code, section VIII, division 1, appendix VI.

5.3.3.3. Ultrasonic inspection

l For the longitudinal welds: ASME code, section VIII, division 1, appendix 12.

l For welding ends, see § 5.3.3.5.

l For base material :

q Procedure: ASME code, section V, art. 23, SA-388.

q Criteria: ASME code, section VIII, division 1, UF-55 (angle probe will be used).

5.3.3.4. Radiographic examination

l For longitudinal seam welds :

q Criteria : ASME code, section VIII, division 1, UW 51

l For girth welds :

q Criteria: API standards 1104, section 6.0.

5.3.3.5. Magnetic particle or liquid penetrant on the finished bevel


l Defects extending into the bevel provided the lamination is parallel to the surface and has a transverse

dimension exceeding 6.35 mm.


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l All defects not parallel to the surface extending into the bevel.

5.4. Fitting & Flange Testing

Hydrostatic testing by the manufacturer is not required, but welding fittings shall be capable to withstand a

field hydrostatic testing in accordance with par. 2.6.

5.5. Workmanship and Finish

5.5.1. Fittings & Flanges shall be free of injurious defects and shall have workmanlike finish.

5.5.2. Injurious defects are defined as those having a depth in excess of 6-1/2 % of specified nominal wall.

5.5.3. Machining and grinding of surface defects shall be treated as follows: sharp defects such as notches,

scratches, scraps, seams, laps, tears, or slivers not deeper than 6-1/2 % of nominal wall thickness

shall be removed by grinding. Repair of injurious defects by welding shall be permitted only after

agreement by the Client and the EPC contractor, except that welding of injurious defects shall not be

permitted when the depth of defects exceeds 33-1/3 % of the nominal wall thickness, or the length of repair

exceeds 25 % of the specified diameter. Defects must be completely removed and welding performed by a

welder qualified specifically for repair welding, as per par. 4.2.1. Such repair welding shall be ground flush

with the surface and all welding shall be done before final heat treatment. Repair welding shall be done

with low hydrogen electrodes in shielded metal arc welding, gas metal arc process or submerged arc

process. In no case, repair welding or cracks nor repair or repairs is allowed. Repair welding will not be

permitted for flanges.

5.5.4. Repair welding shall be done before the last heat treatment. Adjusting weld preparations, intended for field

welding, by means of welding is not allowed. For "standard fitting" repair by welding is not permitted.

5.5.5. Repair welding on the welds & in the body shall be 100 % radiographed and U.S tested.

5.5.6. At the discretion of the TPIA, finished fittings & flanges shall be subject to rejection if surface

imperfections acceptable under par. 5.5.2 are not scattered but appear over an area in excess of what is

considered as a workmanlike finish.

5.6. Marking

5.6.1. All fittings and flanges furnished under this specification shall be clearly identified on the O.D. with the

following information marked with low stress die stamps or interrupted dot stamps as noted (refer to MS

SP25):

l Manufacturer's name or trademark.

l Heat code identity.

l Fitting or flange number: the fitting or flange number shall be made up of six figures specified as

follows: the item and his number specified in the purchase order.


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l The monogram of the EPC contractor. This marking shall only be applied after complete approval of

the Certified Material Test Report (see par. 6.4.).

5.6.2. In addition to the above, for NPS 2" and larger, it shall also include the following information:

l Grade symbol: the grade symbol must designate the material of the fitting or flange.

5.6.3. Marking must be done prior to final inspection.

6. INSPECTION

6.1. Information

The manufacturer shall inform the EPC contractor MIN. 5 working days (15 in case of foreign supplier) in

advance of any intervention required by this specification and shall send a copy (fax) of it to the

Client/Consultant.

6.2. Documentation

Before starting any control, the manufacturer shall submit for approval to the EPC contractor and the

Client/Consultant the following documents:

l Detailed fabrication drawing and calculations.

l Fabrication and control procedure (if new -not if upgraded).

l List of Operations of Control (LOC) in accordance with annex 1(if new -not if upgraded).

l Material list.

l Qualified welding procedures (if new -not if upgraded).

l Welder’s performances qualifications (if new -not if upgraded).

l Heat treatment procedure-(if new -not if upgraded).

l Non destructive testing procedures.

Each company dealing in the order by fabrication and/or control shall implement a LOC for all operations

and interventions performed in its organization. They shall also be responsible for the implementation of

the same by their subcontractors.

6.3. Certified Material Test Report

A Certified Material Test Report (CMTR) shall be furnished listing as built drawing and calculations, the

LOC (see paragraph 6.2.), the proof test certificate, the base material certificate, the chemical check

analysis. The certificate of the heat treatment, the mechanical tests, the non-destructive examination, the

mechanical properties, the quality release note (see paragraph 6.4.) and any special test required by the

purchase order the fitting or flange individual number (see paragraph 5.6.1.) must be indicated in the CMTR

to permit the correct traceability of each piece. The manufacturer shall furnish one copy of the CMTR to

the EPC contractor and one original and one copy to the Client/Engineer.


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6.4. IRN

After final approval of fittings/flanges and the acceptance of the CMTR, the EPC contractor shall furnish to

the Client/Consultant and to the manufacturer an Inspection Release Note (IRN). The manufacturer shall

deliver one copy of the IRN with the fittings/flanges and one copy shall be included in the CMTR (see

paragraph 6.3.).

6.5. Rejection

Each fitting or flange in which injurious defects are found during inspection and after delivery shall be

rejected. The manufacturer shall be notified. In this case, the fitting shall be replaced immediately. All the

costs involved, including wages and travel expenses of the EPC contractor/Client/ Consultant shall be borne

by the manufacturer.

7. CORROSION PROTECTION

The corrosion protection will be applied by the manufacturer after final inspection by the EPC contractor.

The product shall meet the following criteria:

l Guarantee a corrosion protection for a storage period in open air for at least 6 months.

l Shall be easily removable by wire brushing or by grinding.

l It shall not produce toxic vapour or smoke when heated by blow torches or during welding.


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TABLE 1

CHEMICAL COMPOSITION FOR FITTINGS


% MAXIMUM

C 0.230

Mn 1.60

Si 0.50

P 0.030

S 0.025

Nb 0.080

V 0.120

Mo 0.250

Nt 0.0150

Alternate alloy elements may be used but they shall be discussed with the user prior to delivery of the material. This

table is not intended to represent the composition of any heat of steel, but merely to record the maximum permissible

amounts of one element. The combination of elements of any heat must conform to the carbon equivalent, subsection

3.10.2.

For each heat the manufacturer shall analyse the following elements:

C, Mn, Si, P, S, Nb, V, Cr, Mo, Ni and Cu.

The intentional addition of elements other than those specified is not permitted unless agreed upon by the Client.

In any case, for unintentional additions, the following limitations shall be respected :

Cr £ 0.15 % Mo £ 0.05 % Cu £ 0.20 %

Ni £ 0.30 % Co £ 0.01 % Al £ 0.07 %

The content of N total (Nt) may be up to 0.0150 % and must be guaranteed by the manufacturer. If the manufacturer

cannot give any guaranty of N content, he shall analyse this element.


For each reduction of 0.01 % below the maximum carbon content, an increase of 0.05 % manganese above the specified

maximum is permissible, up to a maximum of 1.70 %.


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FIG. 1

Fitting size 24" and smaller may be furnished with 37° ½ bevel at manufacturer's option.

Recommended bevel for wall thickness (t) at end of fitting: 20 mm or less.

FIG. 2

Recommended bevel for wall thickness (t) at end of fitting, greater than 20 mm

L≤

20m

m


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FIG. 3

Note

1. No min. when materialsjoined have equal yieldstrength.

2. t2 must be limited to theminimum

ACCEPTABLE DESIGN FOR UNEQUAL WALL THICKNESS

FIG. 4

TRANSVERSE FACE AND ROOT BEND TEST SPECIMENS

PIPE FITTING


212


FIG 5

GUIDED-BEND TEST JIG DIMENSIONS

CLASS OF STEEL

Y52 and low-grade Y56 Y60 Y70

Radius of male member R A ½ A ½ A ½ A ½ A

Radius of female member R B ½ B ½ B ½ B ½ B

Width of male member, A 4 t 5 t 6 t 8 t

Width of groove in female member, B A + 2t + 3.2 mm A + 2t + 3.2 mm A + 2t + 3.2 mm A + 2t + 3.2 mm

t = specimen thickness

The manufacturer shall use a jig based on this dimension, or a smaller dimension at his option.


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FIG. 6

SPECTACLE FLANGE

S S S

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

PIPELINE VALVES

7 14/09/09 Logo Changed AA PK NC

6 22/09/08 Logo Changed AA PK NC

5 27/01/04 Updated + Logo Changed MRY MRT DKB

4 30/10/02 Updated MRY LEP LEP

3 01/07/02 Updated MRY LEP LEP

2 07/11/01 Updated AES LEP LEP

1 22/06/00 First issue AES LEP LEP

Rev. Date Subject of revision Author Checked Approved

GENERAL TECHNICAL

SPECIFICATION

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Rev. 7 – 14/09/09 Page I of II

TABLE OF CONTENTS

1. SCOPE ........................................................................................................................................ 1

2. DEFINITIONS .............................................................................................................................. 1

3. PRELIMINARY STATEMENT ..................................................................................................... 1

4. GENERAL ................................................................................................................................... 3

5. CODES, NORMS AND STANDARDS ......................................................................................... 3

6. DESIGN AND CONSTRUCTION ................................................................................................. 5

6.1. RATINGS ............................................................................................................................. 5

6.2. DESIGN ............................................................................................................................... 6

6.3. OPERATION ..................................................................................................................... 10

7. MATERIALS ............................................................................................................................. 11

7.1. STEEL USED .................................................................................................................... 11

7.2. PRESSURE RETAINING PARTS ...................................................................................... 11

7.3. BONNET, COVER AND BODY BOLTING ......................................................................... 13

7.4. NON-METALLIC PARTS ................................................................................................... 13

7.5. OTHER PARTS ................................................................................................................. 13

7.6. SOUR GAS SERVICE ....................................................................................................... 13

8. FABRICATION AND TEST ....................................................................................................... 13

8.1. WELDING FABRICATION ................................................................................................. 13

8.2. WELDING PROCEDURES ................................................................................................ 14

8.3. HEAT TREATMENT .......................................................................................................... 15

8.4. MECHANICAL TESTS ON THE PARTS USED FOR WELDING CONNECTION WITH THE LINE PIPES ..................................................................................................... 15

8.5. NON DESTRUCTIVE EXAMINATION (NDE) .................................................................... 16

8.6. PRESSURE TESTING ....................................................................................................... 18

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8.7. OPERATIONAL TORQUE TEST ....................................................................................... 21

8.8. FIRE TEST ........................................................................................................................ 21

8.9. ANTI-STATIC DEVICE TESTING ...................................................................................... 21

8.10. VISUAL AND DIMENSIONAL EXAMINATION ................................................................... 21

9. MARKING ................................................................................................................................. 21

10. INSPECTION............................................................................................................................. 22

10.1. INFORMATION .................................................................................................................. 22

10.2. DOCUMENTS.................................................................................................................... 22

10.3. CERTIFIED MATERIAL TEST REPORT ........................................................................... 23

10.4. QRN 23

10.5. REPAIR ............................................................................................................................. 23

10.6. REJECTION ...................................................................................................................... 23

11. PAINTING AND COATING ....................................................................................................... 23

TABLE I : CHEMICAL COMPOSITION FOR WELDING END OF VALVES

TABLE II : TENSILE REQUIREMENTS OF THE WELDING END OF VALVES

ANNEX I : LOFC (LIST OF OPERATIONS OF FABRICATIONS AND CONTROLS)

S S S

GENERAL TECHNICAL

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Rev. 7 – 14/09/09 Page 1 of 31

1. SCOPE

This General Technical Specification covers the supply of pipeline valves used in high pressure natural gas transport and distribution systems. It describes the general requirements, controls, tests, QA/QC, examination and final acceptance criteria which needs to be fulfilled.

This specification is general and is updated / amended by the Particular Technical Specification dedicated to the project.

2. DEFINITIONS

Engineer : The Entity of the Purchaser or the Company nominated by the Purchaser to design the natural gas transport or distribution system and to specify the equipment.

Purchaser : The Company which makes the purchase order.

Control Authority or CA : The Organisation put in place/requested by the Purchaser/Engineer to proceed to Quality Controls and Certification.

Manufacturer : Manufacturer who receive the purchase order

3. PRELIMINARY STATEMENT

The name of Control Organisation shall be mentioned in the purchase order.

Eventual interpretations and deviations to this specification by the Manufacturer shall be requested by writing in his offer with detailed justification and approved by the Purchaser/Engineer and the Control Authority before the eventual order to the Manufacturer. The latter is responsible and shall indemnify the Purchaser/Engineer for any damage resulting from the non-respect of this obligation.

The specifications of the steel used, the material Manufacturer and all potential subcontractors (such as forging plant, heat treatment, weld fabrication, …) will be described in the offer. After order, no change will be accepted except for justified "force majeure". In that case, the asked changes shall be supported by a technical file submitted to the Purchaser/Engineer for approval.

The Manufacturer shall provide a technical description of the manufacturing method that might influence the quality of the material.

When the order is placed, the Manufacturer shall promptly inform the Purchaser/Engineer about his subcontractor's names, addresses, phone numbers as well as sub-order numbers, extent and delivery terms. On this basis, the Manufacturer shall send a general planning including at least the raw material supply, the manufacturing stages (machining, welding, part assembly, …), testing , painting and packing/dispatching. This planning shall be updated by the Manufacturer at least every month unless otherwise provided in the purchase order. A Dispatcher/Inspector

GENERAL TECHNICAL

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delegated by the Purchaser is entitled to follow, examine and verify the planning's' relevance and effectiveness.

The Purchaser keeps the right to audit the Manufacturers and subcontractor's manufacturing process and control methods. All costs form such an audit shall be borne by the Manufacturer except the wages and travel expenditures of the auditor(s) supported by the Purchaser.

The manufacturing processes and the laboratories, in which welding tests, destructive and non destructive tests are carried out, shall be approved by the Control Authority.

The Purchaser/Engineer and the Control Authority shall have, at any time, free access to all parts of the Manufacturer's facilities and to those of all his subcontractors involved in the order manufacturing. All reasonable means shall be placed at the inspector(s)'s disposal to enable him to check that the product is being manufactured in accordance with this specification. All tests and inspections required in this specification shall be carried out, prior to shipment, in the Manufacturer's plant (or subcontractor's plant) and at the Manufacturer's expenses, unless otherwise provided in the order. The Purchaser/Engineer and the Control Authority shall try not to interfere unnecessarily with other Manufacturer's works when running these tests and inspection.


For any control, test or examination required under the supervision of the Control Authority (LOFC intervention points included), the latter shall be informed in writing FIFTEEN (15) working days in advance by the Manufacturer about place and time with a copy to the Purchaser/Engineer.

If manufacturing is to be carried out under LOFC concept, the Manufacturer shall send for approval a List of Operation in Manufacturing and Control to the Control Authority and Purchaser/Engineer, TEN (10) working days before manufacturing. This list shall be in conformity with the annex 1 to this document. Before starting any manufacturing, the Manufacturer shall be in possession of this approved document, filled in with all intervention points.

Material, even released by the Control Authority and in which injurious defects are found after delivery, shall be rejected. The Manufacturer shall be notified and the material replaced : all costs involved, including wages and travel expenditure of the Control Authority's representative, Purchaser and Engineer shall be borne by the Manufacturer.

An approval of documents can never be considered as an acceptance of deviations on relaxations to requirements. A deviation is only possible after specific request to the purchaser.

GENERAL TECHNICAL

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4. GENERAL

� Valves are intended to be used in aboveground or underground, with cathodic protection services.

All particular conditions for each valve are described in attached data sheet and valve list.

All valves shall conform to API 6D spec. Whenever this specification and API 6D spec. conflict, this specification shall prevail.

Unless otherwise specified, pipeline valves covered by this specification are suitable for use in gas transmission and distribution systems, and in accordance with ASME B31.8.


Latest edition of following standards are applicable.

� ASME STANDARDS

ASME B16.5 Pipe flanges and flanged fittings

ASME B16.34 Valves- flanged and butt welding end

ASME B31.8 Gas transmission and distribution piping systems

� ASTM STANDARDS

ASTM A 53 Pipe, steel, black and hot-dipped zinc coated welded and seamless

ASTM A 105/A 105 M Forgings, carbon steel, for piping components

ASTM A 106 Seamless carbon steel pipe for high temperature service

ASTM A 193/A 193 M Alloy steel and stainless steel bolting materials for high temperature service

ASTM A 194/A 194 M Carbon and alloy steel nuts for bolts for high temperature service

ASTM A 234/A 234 M Piping, fittings of wrought carbon steel and alloy steel for moderate and elevated temperatures

ASTM A 320/A 320 M Alloy steel bolting materials for low temperature service

GENERAL TECHNICAL

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Rev. 7 – 14/09/09 Page 4 of 31

ASTM A 333 Seamless & Steel Pipes for low temperature service

ASTM A 350/A 350 M Forgings, carbon and low alloy steel, requiring notch toughness testing for piping components

ASTM A 370 Mechanical testing of steel products

ASTM A 381 Metal-arc-welded steel pipe for use with high-pressure transmission systems

ASTM A 420/A 420 M Piping fittings of wrought carbon steel and alloy steel for low temperature service

ASTM A 694/A 694 M Forgings, carbon and alloy steel, for pipe flanges, fittings, valves, and parts for high-pressure transmission service

ASTM A 707/A 707 M Flanges, forged, carbon and alloy steel for low temperature service

� API STANDARDS

API 5L Specification for line pipe

API 6D Specification for pipeline valves, end closures, connectors and swivels

API 6FA Fire test for valves

API 605 Large diameter carbon steel flanges

� MSS STANDARDS

MSS SP 6 Standard Finishes for Contact Faces of Pipe Flanges & Connecting – End Flanges of Valves and Fittings

MSS SP 25 Standard marking system for valves, fittings, flanges and unions

MSS SP 44 Steel pipeline flanges

MSS SP 54 Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components Radiographic Examination Method

MSS SP 55 Quality standard for steel castings for valves, flanges and fittings and other piping components (visual method)

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MSS SP 72 Ball valves with flanged or butt welding ends for general service

MSS SP 75 Specification for high test wrought butt welding fittings

� ASME STANDARDS

ASME Boiler and Pressure Vessel code

� EN STANDARDS

EN 10204 Metallic products : types of inspection documents

EN 10045/1 Metallic products : Charpy impact test – test methods (V and U notches)

� ISO STANDARDS

ISO 148 Acier – Essai de résilience Charpy (entaille V)

ISO 9001 : Quality management standard

� BRITISH STANDARDS

BS 5146 Inspection and test of valves

BS 5351 Steel ball valves for the petroleum, petrochemical and allied industries

� NACE STANDARDS

MR0175 Sulphide Stress Cracking Resistant Metallic Materials for Oilfield Equipment.


6.1. RATINGS

1) The pressure temperature ratings of flanged and butt welding end valves shall be in accordance with ASME B16.34.

2) The temperature and pressure ranges of valves shall be in accordance with the indicated values on the appropriated piping specification and valve data sheet.

3) Wall thickness for parts used for the welding connection with the line pipes shall meet the following requirements :

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� The maximum allowable stress in the material of the butt weld connection for butt welding end valves shall be equal to fifty per cent of the minimum yield strength guaranteed by the specification of the steel used.

� The minimum wall thickness for butt welding connection must be greater than or equal to the largest value of either the calculated minimum thickness of butt welding connection or the nominal thickness of the pipe as indicated on data sheet.

� If the butt welding connection has a yield strength lower than the yield strength of the pipe to which it is intended to be welded, the wall thickness in each zone of the butt welding connection is at least equal to the specified pipe wall thickness times the ratio of the minimum yield strength guaranteed by the specification of the steel of the pipe and the minimum yield strength guaranteed by the specification of the steel of the butt welding connection.

� The specified pipe wall thickness and grade (with reference to the equivalent grade in API 5L spec. or ASTM spec.) with which the valve is intended to be used is specified in the data sheet/piping class.

4) The Manufacturer shall submit for approval to the Control Authority and to the Purchaser/Engineer the dimensional drawings, the calculation of the parts used for the welding connection to the pipeline and the material part list for all the types of valves. All these documents must be identified with the individual valve number according to attached valve list and shall be attached to the CMTR.

5) The design shall take into consideration performance requirements prescribed in the next paragraph.

All valves under this specification shall be designed to withstand a field hydrostatic test pressure with non corrosive water, after installation, during 24 hours when the gate, plug, ball or piston is partially or fully open at a pressure of 1.5 times the 38OC pressure rating gauged by ASME B16.34

During this test the closure element shall not be moved.

6.2. DESIGN

6.2.1. Face-to-face and end-to-end dimensions

Face-to-face and end-to-end dimensions for ball valves shall be in accordance with API spec. 6D.

Valves may be made to special dimension by agreement between the Manufacturer and the Purchaser.

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6.2.2. Welding ends

The connecting pipe outside diameter, wall thickness, specified minimum yield strength and material grade are mentioned in the relevant piping specification and valve data sheet.

Butt-welding ends shall be in accordance with figure 1 for wall thickness up to 20.0 mm; for thicker walls, refer to figure 2. The inside diameter at the welding end shall be equal to that of the pipe on which the valve shall be welded. If a welding end of a valve has a thickness not equal to the pipe with which it is intended to be used, the welding end preparation at the joint has to be in conformity with fig. 3.

The tolerance of the inside diameter at the bevel end shall be following :

NPS Tolerance of inside diameter at bevel end (1) (mm)

2" - 10"

12" - 48"

+ 1.6

+ 2.4

-0.4

-0.8

(1) Tolerance refers to variation from specified ID calculation by (OD spec. - 2t spec). OD = outside diameter t = wall thickness

The out-of roundness at a welding end, defined as the difference between the maximum and the minimum inside diameter at the welding pipe end shall not exceed 1% of the specified inside diameter.

The length of the butt end shall be sufficient to allow welding and heat treatment without damage of the internal parts of the valve. If Purchaser/Engineer accepts design which do not meet this requirement, than Manufacturer shall inform the Purchaser/Engineer about the precautions which needs to be fulfilled in order to guarantee that during welding of the butt welding ends no damage shall occur to the seat. These precautions shall be highlighted by the Manufacturer in the erection and installation instruction book.

6.2.3. End flanges

End flanges shall be furnished in the same class as the valve body with raised face or ring-joint face, as specified by the valve data sheet. Dimensions and tolerances (including drilling templates, flange facing, spot facing and back facing) shall conform to :

� ASME B16.5 standard for NPS 24" and smaller

� MSS SP-44 for NPS 26" to 60"

� MSS SP-6 for flange facing.

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6.2.4. Design features

All ball valves shall be full bore - to allow pigging - unless stipulated otherwise on the valve data sheet.

All trunnion mounted ball valves shall be fitted with following devices :

� Double block and bleed : design of a valve with two seating surfaces between which the cavity can be vented through a bleed connection and thus confirm the tightness of the valve, at least in closed position, when pressure is applied to any side or both sides of the valve.

� Double piston effect : when the pressure is applied to one side, let us say "upstream" side, and when upstream ball seat is leaking, transfer pressure shall have a positive shut-off effect on the downstream seat (acting, for instance, on the back face of this seat) and thus reinforcing the global tightness of the valve.

� Anti-static design : all ball valves shall be fitted with anti-static device conforming to BS 5351.

� Stem retention (anti blow-out) : In conformity with BS 5351 valve shall be designed with an anti blow-out stem so that the stem cannot be fully ejected by pressure inside the valve with the stem packing, gland retainer bolting removed.

� Secondary seat and stem sealing : all ball valves NPS 6" shall be fitted with a secondary stem sealing and all ball valves greater or equal to NPS 8" shall be fitted with a secondary seat and stem sealing. This system permits an injection of sealant and shall be fitted with an integral check valve. The number and the location of sealing points shall be on the Manufacturer's responsibility.

Purchaser is allowed to request the check of this system design and its operation, specially for modified or new valve model.

� A drain connection shall be located at the lowest part of the body cavity.

6.2.5. Auxiliary connections

The Manufacturer shall complete the valve data sheet with the size and allowable pressure for the following auxiliary piping connections.

a) Aboveground valves

� The drain shall be plugged.

� The vent/bleed connection for valves NPS 6" and above shall be equipped with one block valve plus one needle valve, each with anti blow-out stem. The block valve shall be of ball type. The needle valve shall have screwed connections, shall be preferably of angular pattern and shall be fitted with a special plug at the outlet : this plug shall be designed to relieve slowly the pressure without being ejected.

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� For valve size < NPS 6", the vent/bleed connection shall be equipped with this anti blow-out, depressurising plug only.

� Each secondary stem - and each secondary seat sealing device, when required (see § 6.2.4.), shall be fitted with a check valve integrated in the body plus a sealant fitting with built-in, spring loaded ball check valve, as mentioned in the valve data sheet.

b) Underground valves

� Vent/bleed connection shall be plugged and this functionality is by passed through the drain.

� Drain shall be fitted with a normally open block valve (ball type with anti blow-out stem) at the drain tap, piped to the upper part of the extension and ended by one ball valve plus one needle valve, each with anti blow-out stem.

� The needle valve shall have screwed connections, shall be preferably of angular pattern and shall be fixed with an anti blow-out, depressurising plug, at the outlet.

� Each stem and seat sealing connection, when required (see § 6.2.4) shall have a check valve integrated in the main valve body, a block valve (ball type with anti blow-out stem) closed to the body tap, shall be piped up to the upper part of the extension and equipped with a block valve (same type) plus a sealant fitting with built-in, spring loaded check valve, as mentioned in the valve data sheet.

� Valves and tubing shall be carefully fastened to the valve body and/or extension.

Valve bodies shall have tapped holes with a minimum effective threaded engagement at least equal to the nominal thread diameter. If body wall thickness is too thin, then unthreaded side of OEP/OET (One End Plain/One End Threaded) piece of pipe of a material compatible with the body, shall be welded to the valve body with full penetration or via a boss. Anyway, weld on threads is prohibited.

Material of auxiliary connections (pipe, tube, fittings, valve, …) shall be, at the least of the same material quality as the main valve and can be in stainless steel series AISI 300.

6.2.6. Stem extension for underground valve

When a stem extension is required (see valve data sheet), the configuration and the length H shall be in accordance with this valve data sheet.

In this case and except otherwise specified in the purchase order, valves shall be fitted with drain and sealant extensions well fixed to the stem extension and clearly indicated in the as built design. The stem extension shall be fully watertight, but shall be provided with a means to prevent overpressure built up in the mechanism resulting from stem or bonnet seal leakage.

Valves, equipped with stem extension and/or actuator, shall be delivered completely equipped and mounted (in one piece).

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Underground actuated valves shall be provided with one identification plate on the valve body and one on the upper part of the extension.

6.2.7. Miscellaneous

Lifting lugs are required on all valves NPS 6" and larger. The lifting lugs shall be stamped with the safe working load. Number of lugs shall be sufficient for safe handling on site. Valve support : All valves greater than NPS 24" shall be equipped with supports to permit the installation of the valve in horizontal position directly on the floor. These supports shall be directly welded or fitted on the body of the valve.

6.2.8. Design review

The Manufacturer shall submit for approval to the Engineer/Purchaser and Control Authority the calculation for all bonnet, cover and body bolting for pressure retaining parts conforming to ASME B16.34.

6.3. OPERATION

6.3.1. Valve shall be operated by a hand-wheel, wrench, manual key or actuator.

Manual override devices shall be provided on all valves. Hand-wheels of electric actuators, shall be normally disengaged and shall automatically disengage when the actuator is operated.

6.3.2. The length of the wrench or diameter of the hand-wheel for direct or gear operated valves shall (after opening and closing a new valve at last three times) be such that a force not exceeding 350 N shall be required to operate the ball from either the open or closed position under the maximum differential pressure recommended by the Manufacturer.

For valves without stem extension equipped with a hand-wheel in vertical position, the maximum radius of the hand-wheel is equal to the distance between the centre line of the pipe and the centre of the hand-wheel minus 120 mm. In this case no extruding lugs on hand-wheel are permitted, and provision for by-pass valve shall be kept.

6.3.3. Hand-wheel shall be marked to indicate the direction of closing.

6.3.4. Hand-wheels and wrenches shall be fitted in such a way that whilst held securely they can be removed and replaced where necessary.

6.3.5. All ball valves shall be provided with a mark on the stem to show the position of the ball in order to enable a good regulation of the actuator without seeing the ball. Exception can be made for valves with gear boxes for underground service.

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6.3.6. Ball manual direct operated valves shall be fitted out with fully open and fully closed stops. These stops shall be well fixed to the body of the valve in order to withstand many extreme opening and closing actions. These stops shall be easily removable. Ball gear operated valves shall be fitted out with fully open and fully closed stops shall be adjusted and fixed on the gear box.

6.3.7. The Manufacturer shall advise the maximum operating torque or force which can be sustained without causing permanent damage anywhere in the drive train from the actuator to the obturator. The Manufacturer shall also provide the torque graph : torque value in function of opening angle of the ball and pressure.

Deflection in the extended drive train must be limited so that the closing position contact reflects exactly the real position of the obturator.

6.3.8. Maximum rated differential pressure (MRDP)

The MRDP is the maximum difference between the valve upstream and downstream pressure at which the obturator (closure member) may be operated (opening). The Manufacturer shall specify this value and shall mark it on the valve name plate.

For the specification of different types of actuator refer to the concerned GTS/740/403.

7. MATERIALS

7.1. STEEL USED

The steel used in the valve Manufacturing shall be selected by the Manufacturer and filled in data sheet form

This list shall be submitted for approval to the purchaser/Engineer at the time of the offer. This list shall be added to the CMTR.

7.2. PRESSURE RETAINING PARTS

For pressure retaining parts the following requirements must be fulfilled

7.2.1. Bodies, including end flanges and welding ends (other than for field welding), bonnet and covers of valves shall be made in material conforming to API 6D spec. (or another material specification accepted by the Purchaser/Engineer) and be furnished with certificates EN 10204-3.1. B stating the quality, the mechanical properties (yield strength, tensile strength, percent elongation, impact test value at the temperature specified under per Section 8.4.2), the chemical analysis, the manufacturing process and the marking (e.g. the heat number) of the steel. These certificates shall be added to the CMTR.

For the valves with butt welding end, for the part on which the line pipe shall be welded, see paragraph 7.2.4. and 8.4.

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7.2.2. Notch toughness properties

The impact test temperature conditions and temperature are defined under Section 8.4.2.

7.2.3. The carbon content of parts involved in welding operation (except for those parts which shall be used for the welding connection with the line pipes) shall be restricted as follows :

� maximum percentage of carbon : 0.230

� C + Mn6

≤ 0.41

7.2.4. For parts used for the welding connection with the line pipes the following supplementary requirements must be fulfilled :

� The chemical composition of the steel meets the requirements of table 1. The choice and use of alloying elements made from high strength low alloy steels to give the tensile properties prescribed in table 2 shall be made by the Manufacturer and included and reported to identify the type of steel.

� For each heat, the Manufacturer shall analyse the following elements : C, Mn, Si, P, S, Nb, V, Cr, Mo, Ni and Cu.

� The carbon equivalent shall be computed by the following equation :

C.E. = C + Mn6

+ Cr Mo V+ +

5 +

Ni Cu+15

and shall not exceed 0.45.

� The steel used shall be fully killed, fine grain practice.

� The steel used shall be suitable for field welding to pipes, flanges or fittings manufactured under ASTM A53, A105, A106, A234, A333, A350, A381, A420, A694, A707 or API 5L, 605 or MSS SP-44, SP-72, SP-75, EN10208-2.

� The steel used has tensile properties conforming to requirements prescribed in table 2 and capable of meeting the valve design.

� The ratio of yield strength to tensile strength shall not exceed 0.85.

� Mechanical tests as prescribed in section 8.4. shall be performed after final heat treatment.

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7.3. BONNET, COVER AND BODY BOLTING

Bonnet flange cover, and body bolting shall be conform to ASTM A320 Gr L7 or L7M or ASTM A193 grade B7 or B7M. Nuts shall be conform to ASTM A194 Gr 7 or 7M or 2H. For NPS greater than 4", they must be supplied with certificates EN 10204-3.1.C. and for NPS 4" and smaller with certificates EN 10204.3.1.B. These certificates shall be added to CMTR.

Bolt design shall be done to withstand safety all stresses occurring under operating conditions, calculations shall be submitted for approval.

Materials shall be compatible in order to avoid galvanic corrosion and shall not be susceptible to hydrogen embrittlement or stress corrosion cracking. Manufacturer must take into account that the materials shall be eventually cathodic protected.

7.4. NON-METALLIC PARTS

Non-metallic parts and elements, which usually include such items as packing, injectable material and lubricants, shall be suitable for the service and must be defined in the offer.

7.5. OTHER PARTS

Metal parts, which usually include such items as yokes, yoke nuts, stems, glands, gland bushing, gates, balls, plugs, discs, pistons, hand-wheel, gearing and motor drive attachments, shall be of material suitable for the service and must be defined in the offer.

7.6. SOUR GAS SERVICE

When sour gas service or NACE is specified, all process wetted, pressure containing parts and bolting shall meet the requirements of NACE MR0175.


Prior to manufacturing a meeting shall be organised between Manufacturer, Purchasing agent, Engineer and Control Authority.

8.1. WELDING FABRICATION

1) Welds and repair welds shall be performed according to written procedures. The welding procedure must be submitted for approval to the Control Authority before any fabrication and/or repair.

2) Only welders and welder operators who are qualified shall be used in production.

3) The joints shall be furnished in accordance with the requirements of Section VIII of ASME Boiler and Pressure Vessel Code - Division 1.

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4) The machine welding shall be done by an electric process, preferably by submerged arc.

5) Repair by welding is prohibited on forged material.

8.2. WELDING PROCEDURES

8.2.1. All welds, repair welds and repair by welding shall be performed according to written procedures. These welding procedures shall be qualified according to the requirements of the ASME Boiler and Pressure Vessel Code, Section IX.

The welding procedure tests are required on material which is on the high side of the chemistry specification.

The Manufacturer shall maintain a weld record of the procedure and performance test results.

For the tensile test, the rupture of the specimen must take place in the unaffected parent material.

The welding procedure qualification must include an impact test set in the weld and in the HAZ with requirements of paragraph 8.4.2. and a macrographic examination described in paragraph 8.2.2. These tests shall be performed after eventual final heat treatment. If weld thickness is higher than 25 mm, even covered by the PQR, additional impact test shall be performed on the test specimens taken in weld thickness layers.

8.2.2. Macrographic examination : the etched surface of the macro test specimen viewed macroscopically must display the image of a well performed welded joint with sufficient penetration, free from linear defects and important inclusions. In case of doubt, the etched surface must be examined microscopically and additional macroscopic examinations of other areas may be required.

The macrographic examination will include hardness measurements in the weld and the HAZ. The hardness will not exceed the values measured on the parent metal by more than 80 points for the welds and 100 point for HAZ, with an absolute maximum of 350HV10.

The acceptance of inclusions can be decided upon with the NDE of the welded plates (see paragraph 8.5.).

8.2.3. Additional requirements for "Sour Gas". Qualified welding procedure shall guarantee a good geometry without stress concentration and shall be realised according to NACE MR 0175 (max. 1% Ni in welding consumables).

On the macro, series of hardness tests shall be performed in the base metal, weld and Heat affected zone; results shall be maximum 248HV10.

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8.3. HEAT TREATMENT

8.3.1. After hot working and before re-heating for normalising heat treatment, forging or casting shall be allowed to cool substantially below the transformation range. All forging or casting shall be heat treated by normalising. Normalising shall be carried out in such a way that the base material acquires a fine grained perlitic structure.

8.3.2. Heat treatment of welds : the rules of ASME VIII Div. 1 are applicable. If a required treatment is not feasible (seat damage, etc, …), special agreement must be obtained from Purchaser/Engineer and Control Authority ACA, after the Manufacturer has proved good quality of welds.

8.3.3. The Manufacturer shall include in the CMTR data of this heat treatment.

8.4. MECHANICAL TESTS ON THE PARTS USED FOR WELDING CONNECTION WITH THE LINE PIPES

The following mechanical tests shall be performed on these parts after final heat treatment under the supervision of the Control Authority's delegate and the certificates shall be added to the CMTR.

Test specimens may only be cut after a marking transfer by the Control Authority.

8.4.1. Tensile testing

Requirements :

The material shall be in conformity with table 2. The ratio of yield strength to tensile strength shall not exceed 0.85.

Test specimen :

The test specimen represents any part of the same shape, the same heat of steel and the same heat treatment lot.

Number of test : one

Test location and orientation :

The test specimen shall be orientated transversally to direction of lamination and if this orientation is not feasible, it shall be orientated longitudinally. For castings only one orientation is applicable.

Test method :

Testing shall be performed in accordance with ASTM A370 standard rectangular plate type 1 1/2" wide (fig. 4 - A370) or standard round (fig. 5 or fig. 6 - A370).

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Yield strength shall be determined either by the 0.2 % offset or the 0.5 % extension under load (EUL) method. If another material are accepted by the Purchaser, the test method will be as specified in the material specification.

8.4.2. Impact test

Requirements :

The standard impact test temperature is -20°C, except if otherwise stated in the "Material Requisition" or particular Technical Specification. The average value of a set of 3 test specimens shall be equal to 35 J/cm². The minimum value per test specimen shall be equal to 35 J/cm² but this value may drop to 28 J/cm² for only one test specimen per series.

� Test specimen :

The test specimen represents any part of the same shape, the same heat of steel and the same heat treatment lot.

� Number of tests :

2 test sets (3 test specimens constitute one test set). For castings only 1 test set.

� Test location and orientation :

1 set shall be orientated longitudinally and another one transversally. For castings only one orientation is applicable.

� Test method :

The notched bar impact test shall be performed in accordance with ISO 148 or A370- Charpy V - Notch.

If the wall thickness of these parts or the coupon does not enable machining of full size specimens, the largest possible size must be used but not less than (10 x 5) mm. The axis of the notch shall be orientated through the wall thickness of these parts. If the weld thickness is > 25 mm, several specimen sets shall be taken in the weld thickness with min one (1) set per 12.5 mm of thickness, the specimen sets shall be selected in agreement with the Purchaser/Engineer and Authorised Control Authority.

8.5. NON DESTRUCTIVE EXAMINATION (NDE)

The following NDE will be performed after the final heat treatment and before coating.

8.5.1. List of NDE

� All butt welds shall be examined by a radiographic examination. If the thickness exceeds 15 mm or if the radiographic examination is not feasible than welds are only examined by ultrasonic examination to the largest extent possible.

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The radiographic examination shall be executed in accordance with ASME Boiler and Pressure Vessel Code, section V, art. 2 - using fine grain film and lead screens.

� Butt welding ends on cast bodies shall be examined before fabrication welding end, by radiography in accordance to MSS-SP-54 and over a width of 70 mm.

� 25 mm of base material at each side of each weld and each weld shall be 100 % ultrasonically examined.

The ultrasonic examination shall be executed in accordance with ASME Boiler and Pressure Vessel Code, section 5, art. 5.

� Body for all valves NPS 6" and greater shall be tested by magnetic particle examination in conformity with ASME Boiler and Pressure Vessel Code, section V, art. 7.

� All valves shall be visually examined.

� All valves shall be dimensionally examined.

� For butt welding end valves after machining, the finished bevel end pipe used for field welding shall be submitted to the following tests :

� Magnetic (ASME V Art. 7) or liquid penetrant (ASME V Art. 6).

� Ultrasonic inspection (ASME V Art. 5) or radiographic examination (ASME V Art. 2)on 25 mm of base material.

� Visual and dimensional examination.

� If any repair by welding is performed, the concerned parts shall be completely re-examined.

8.5.2. Additional NDE requirement for "SOUR Gas"

A series of hardness test on surfaces in contact with the fluid shall be performed to NACE MR 0175. Results shall be 22 HRC or 248 HV 10 max.

8.5.3. Acceptance criteria of the different NDE

� Radiographic examination :

ASME Boiler and Pressure Vessel Code, section VIII, division 1, UW 51 for forged steel

ASME Boiler and Pressure Vessel Code, section VIII, division 1, appendix 7 for casted steel. The control will done on width of 70mm with.

On the first 40mm A1,B1,C1 acceptable, D, E, F and G are rejected.

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Between 40mm and 70mm, A2, B3, C3 acceptables; D, E, F, G are rejected.

� Ultrasonic inspection of weldings and HAZ:

ASME Boiler and Pressure Vessel Code, section VIII, division 1, Appendix 12.

� Magnetic particle inspection of the body:

ASME Boiler and Pressure Vessel Code, section VIII, division 1, Appendix 6.

For casted pieces refer to Appendix 7.

� Visual examination

MSS-SP-55.

� Magnetic particle or liquid penetrant of the finished bevel:

The following defects are unacceptable :

� Defects extending into the bevel provided the lamination is parallel to the surface and has a transverse dimension exceeding 6.35 mm.

� All defects not parallel to the surface extending into the bevel.

All the NDE (except radiographic examination) shall be performed under the supervision of the control authority's delegate and the certificates shall be added to the CMTR.

8.6. PRESSURE TESTING

8.6.1. General requirements

� Each valve shall be tested by the Manufacturer under the supervision of the Control Authority after final completion of all welding and all heat treatment operations.

� Hydrostatic and air seat test 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 50°C.

� Valves shall be substantially relieved of air when tested with liquid.

� Valves shall be shell tested prior to painting.

� 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.

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� 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.

8.6.2. Shell test

� Each valve shall be given a shell test at the gauge pressure not less than 1.5 times the 38°C 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 are not accepted.

8.6.3. Hydrostatic seat test

� Each valve shall be given a hydrostatic seat test at the gauge pressure not less than 1.1 times the 38°C rating gauged by ASME B16.34, rounded off to the 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 soft seated valves there shall be no visible leakage - for metal seated valves the leakage rate shall not exceed 0.006 ml per minute and per mm of nominal pipe size (ND).

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� 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.

� 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 are not accepted.

8.6.4. External leak testing

Under the supervision of the Control Authority's delegate, 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 bar. For underground valves, this test shall include piping, fittings and valves of the auxiliary lines for drain, vent/bleed and sealant connections.

8.6.5. Air seat test

� Each valve shall be given an air seat test at 6 bar.

� 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.

8.6.6. Procedure

Procedure of all pressure tests shall be included in the offer.

8.6.7. After tests

After test, any auxiliary connections shall not be removed, and auxiliary piping shall be cleaned and dried, especially the sealant piping.

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GTS/402

Rev. 7 – 14/09/09 Page 21 of 31

8.7. 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.

8.8. 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.

8.9. ANTI-STATIC DEVICE TESTING

If requested in the purchase order, all ball valves shall be submitted of to an anti-static electricity testing in accordance with BS 5146 and this certificate shall be added to the CMTR.

8.10. VISUAL AND DIMENSIONAL EXAMINATION

All valves shall be visually and dimensionally examined, according to API 1104 and MSS-SP-55.

9. MARKING

9.1.1. All valves supplied under this specification shall be clearly identified on the body, on the identification plate and on the valve flange edge.

9.1.2. Body markings

The following markings shall be cast, stamped, forged or engraved on the body of the valve :

c) Manufacturer's name or trademark.

Individual tag number according to attached valves list.

The monogram of the Control Authority. This marking shall only be applied after complete approval of the CMTR.

Flow direction on unidirectional valve.

9.1.3. Permanently attached identification plate markings

On minimum the following markings shall be shown on permanently attached identification plates :

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 22 of 31

a) Manufacturer's name or trademark.

b) Individual valve fabrication number (serial number).

c) Individual tag number.

d) The maximum operating pressure;

e) The min and maximum operating temperatures

f) Body material designation (conforming MSS SP-25).

g) Rating designation (conforming ASME B16.34).

h) Valve trim identification (conforming MSS SP-25).

i) Nominal valve size.

j) Monogram of the Control Authority.

10. INSPECTION

10.1. INFORMATION

The Manufacturer shall inform the Control Authority min. five (5) working days in advance of any intervention required by this specification and shall send a copy of it to the Purchaser/Engineer (by fax).

10.2. DOCUMENTS

Before starting any fabrication, the Manufacturer shall submit for approval to the Control Authority and the Purchaser/Engineer the following documents :

� Detailed fabrication drawing and calculations.

� Fabrication and control procedure.

� Qualified welding procedures;

� Welders performances qualifications;

� NDT procedures;

� List of Operations in Fabrication and Control (LOFC) in accordance with annex 1.

Each company dealing in the order by fabrication and/or control shall implement a LOFC for all operations and interventions performed in its organisation. They shall also be responsible for the implementation of the same by their subcontractors.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 23 of 31

10.3. CERTIFIED MATERIAL TEST REPORT

A Certified Material Test Report (CMTR) shall be furnished listing as built drawings and calculations, the LOFC (see paragraph 10.2.), the base material certificate, the chemical check analysis of the welding ends. The certificate of the heat treatment, the mechanical test, the non-destructive examination, the pressure testing, the operational torque test, the quality release note (see paragraph 10.4.) and any special test required by the purchase order. The valve individual number (see paragraph 9.1.2.) must be indicated in the CMTR to permit the correct traceability of each valve. The Manufacturer shall furnish one copy of the CMTR to the Control Authority's delegate and one original and one copy to the Purchaser/Engineer.

10.4. QRN

After final approval of valves and the acceptance of the CMTR, the control authority's delegate shall furnish to the Purchaser/Engineer and to the Manufacturer a Quality Release Note (QRN). The Manufacturer shall deliver one copy of the QRN with the valves and one copy shall be included in the CMTR (see paragraph 10.3.).

10.5. REPAIR

Defects in material may only be repaired provided written acceptance by the contracting parties and the Control Authority has first been obtained.

This written acceptance must be given case per case. Defective material, that cannot be satisfactory repaired or repaired without written approval shall be definitively rejected.

10.6. REJECTION

Each valve in which injurious defects are found after delivery shall be rejected. The Manufacturer shall be notified. In this case, the valve shall be replaced immediately. All the costs involved, including wages and travel expenses of the Control Authority's delegate shall be borne by the Manufacturer.

11. PAINTING AND COATING

The surface of the valve will be shot-blasted SA 2 1/2 (Swedish standard SIS 055900). Before painting, the valve shall be cleaned from grease and dirt. The painting shall consist of a primer coating (30 - 40 µm) and a finish coating (30 - 40 µm).

The nature of the products shall be specified in the offer and shall guarantee a corrosion protection for a storage period in a shop for at least one year.

Painting in accordance with Purchaser/Engineer's specifications.

Painting and coating procedures shall be submitted for approval before manufacturing to the authorized Control authority and to the purchaser / engineer.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 24 of 31

For underground valves the Manufacturer shall propose an adequate protection at the time of offer. This adequate protection shall be in accordance with the Purchaser/Engineer's specification.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 25 of 31

TABLE 1

CHEMICAL COMPOSITION FOR WELDING END OF VALVES


% Maximum

C 0.230

Mn 1.60

Si 0.50

P 0.030

S 0.025

Nb 0.080

V 0.120

Mo 0.250

Nt 0.0150

Alternate alloy elements may be used but they shall be discussed with the user prior to delivery of the material. This table is not intended to represent the composition of any heat of steel, but merely to record the maximum permissible amounts of one element. The combination of elements of any heat must conform to the carbon equivalent, subsection 3.2.4.3.

For each heat the Manufacturer shall analyse the following elements :

C, Mn, Si, P, S, Nb, V, Cr, Mo, Ni and Cu.

The intentional addition of elements other than those specified is not permitted unless agreed upon by the Purchaser.

In any case, for unintentional additions, the following limitations shall be respected :

Cr ≤ 0.15 % Mo ≤ 0.05 % Cu ≤ 0.20 %

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 26 of 31

Ni ≤ 0.30 % Co ≤ 0.01 % Al ≤ 0.07 %

The content of N total (Nt) may be up to 0.0150 % and Must be guaranteed by the Manufacturer. If the Manufacturer cannot give any guaranty of N content, he shall analyse this element.


In grades X42 through X60 for each reduction of 0.01 % below the maximum carbon content, an increase of 0.05 % manganese above the specified maximum is permissible, up to a maximum of 1.70 %.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 27 of 31

TABLE 2

TENSILE REQUIREMENTS OF THE WELDING END OF VALVES

CLASS

SYMBOL

FIELD STRENGTH (min)

TENSILE STRENGTH

(min)

ELONGATION in 2" min. %

KSI MPa KSI MPa

B 35 241 60 413 25

X42 42 289 60 413 25

X46 46 317 63 434 25

X52 52 358 66 455 25

X60 60 413 75 517 20

The ratio of effective yield strength to effective tensile strength of the steel shall not exceed 0.85.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 28 of 31

Figure 1

Figure 2

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 29 of 31

Figure 3

ACCEPTABLE DESIGN FOR UNEQUAL WALL THICKNESS AT WELDING END OF VALVE

Notes

(1) No minimum when materials joined have equal yield strength.

(2) Dimension to be limited to a minimum.

When the minimum specified yield strengths of the sections to be joined are unequal :

� the deposited weld metal shall have mechanical properties at least equal to those of the section of the higher strength.

� tD shall be equal to at least t times the ratio of min. specified yield strength of pipe by those of welding end of valve.

� tD ≥ tx valvetheofendweldingtheofsteeltheofdardtansthebyguaranteedstrengthyield.Min

pipetheofsteeltheofdardtansthebyguaranteedstrengthYield.Min

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 30 of 31

ANNEX 1

LOFC (LIST OF OPERATIONS OF FABRICATIONS AND CONTROLS)

Each LOFC must contain the following information as a minimum (all clearly marked and separated) :

k) Company name and references relating to the order.

l) All technical and other information required in order to define the items covered.

The area of application will be limited to that item or those considered as in fabrication and control.

m) A numerical sequence of operations with description will be built-up in a logical way of work progress.

� The first operation will be the control of the incoming material(s) and documents.

� The last operation will be the control of the CMTR.

The following operations have to be included (not limited to) :

� Each fabrication step.

� Each step which calls for own quality control (eventually QA).

� Each applicable examination as part of this specification.

� Document controls - stamping and final documentation.

n) Each operation will be followed by the applicable specification or procedure number (with the latest revision).

o) Columns to be provided for possible interventions of :

� the Manufacturer's fabrication control,

� the Manufacturer's quality control (eventually QA),

� Control Authority,

� the Purchaser/Engineer,

and place of intervention if not by the Manufacturer.

The interventions will be indicated per operation with H or W and/or R.

H = hold point No further steps may be undertaken before the intervention of the appointed responsible takes place.

GENERAL TECHNICAL

SPECIFICATION

70000 740

GTS/402

Rev. 7 – 14/09/09 Page 31 of 31

W = witness point The appointed responsible has to be notified of the operation in advance, but production will continue whether the intervention took place or not.

R = point for which a control report or a recording has to be made.

The Manufacturer will fill in his own H, W and R points. The Control Authority and the Purchaser/Engineer will do the same in their designated columns, but this will not implicate a relaxation or wearing of the requirements of the Manufacturer's controls.

Each intervention has to be signed and dated by the person acting as controller. Only the original documents will be presented for this purpose.

p) One column to be provided for report or record numbers (points marked R) and one for the review of these documents by the Control Authority.

q) Two extra columns may give reference to a non-conformity report if any and to the resolution given to it.

Completion of the LOFC does not automatically give rise to a release of the material or it must be stipulated otherwise in the contract.

S S S

I GENERAL- VALVE MANUFACTURER -- ACTUATOR MANUFACTURER NA

II VALVE DESIGN CONDITIONS- CORROSSION ALLOWANCE- SERVICE Gas- DESIGN PRESSURE (Barg)- TEMPERATURE (°C)

III. CONNECTING PIPE DETAILS 2 " OD- MATERIAL ASTM A333 GR. 6- DIAMETER (OD)- THICKNESS Sch. 160

IV. VALVE CONSTRUCTION DESIGN :- APPLICABLE SPECIFICATION PTS - PIPELINE VALVES (P.013828 D 11077 209) & GTS 70000/740/GTS/402 Rev. 07- CONSTRUCTION DESIGN API 6D- PIPE CLASS 6C1- RATING 600 #- INSTALLATION ABOVE GROUND- VALVE BORE FULL BORE- VALVE BODY FULLY WELDED / BOLTED- TYPE TRUNNIOUN MOUNTED DOUBLE BLOCK & BLEED- VALVE OPERATION WRENCHED OPERATED- END CONNECTION RF (As per ANSI 16.5)- FACE FINISH (Flanged End) 125 AARH

V VALVE MATERIAL SPECIFICATION

PART DESCRIPTION- BODY MATERIAL ASTM A350 GR. LF2 CL.1 / ASTM A352 GR. LCC

- BALL MATERIAL

-

- SEAT SEAL- STEM (No Casting)- STEM SEALS- Primary seat- Secondary Seat- ANTI-BLOW OUT- LENGTH OF EXTENSION STEM

- PUPS (Applicable only for BW end)Length :Material of ConstructionThickness

- PAINTINGSurface preparationPrimer

Finish- INSULATION NO

REV CHECK BY APPR BY00 MS SKH

*

Issued for RFP

*

*

OFFERED MATERIAL

P.013828 D 11088 002

92

VITON / DEVLON or equivalent

PTFE / VITON or equivalent

PREP BYMK

*

BODY SEAT RINGS (NoCasting)

- 45 to 65

Page 1 of 2

DATA SHEETFOR

BALL VALVES ( 2" SIZE)

DATA SHEET No. 6C1

YES

AISI 4140 with 75 micron ENP COATING / AISI 410

SPECIFIED MATERIAL

2 mm

Not Applicable


Type of paint, DFT and total DFT shall be as per paint system no. chosen from Table A5, ISO 12944-5 suitable for highly corrosive environment. Final shade ofvalve shall be as per Painting specification no. P.013828 D 11077 207.Final Paint DFT - 320 Microns minimum

Metal to Metal

DESCRIPTION

NANA

RPTFE / DEVLON or equivalent

23.04.2019DATE

ASTM A 182 Gr. F316 OR ASTM A351 Gr. CF8M OR (ASTMA350 GR. LF2 CL.1 / ASTM A 352 GR.LCC) + ENP

60.3 mm

NA

SA 2.5

**

NA

Rev-0 Laying and Associated Works For HMEL Connectivity Pipeline Project Page 1 of 2

VI.

- HYDROSTATIC SHELL TESTTest pressure : 1.5 x Design Pressure Test Duration :

- HYDROSTATIC SEAT TESTTest pressure : 1.1 x Design Pressure Test Duration :

- PNEUMATIC SEAT & SHELL TEST

Test Duration

- AIR SEAT TEST : 7 Bar(g) Test Duration

- FUNCTIONAL TEST

Test pressure : At 90 barg Test Duration

- HELIUM TEST : 25% of Rated pressure Test Duration : 30 mins.(As per ASME Secv , Subsection A, Article 10 , Appendix IV)

- LEAK TEST : API 598

- DOUBLE BLOCK & BLEED TEST : Yes

- TORQUE TEST : API 6D

- ANTISTATIC TEST : BS - 5351 / API 598

- FIRE TEST : API 6FA

- : MSS-SP-55

VII QUALITY CONTROL

- MATERIAL CERTIFICATES :

- TEST CERTIFICATES :

NOTES:-1 Stem height will be finalised/decided during detail engineering, If applicable

2 Unless otherwise stated, all tests will be witnessed by the TPIA

3

4 Valve shall have position indicator showing open and close positions.

5 High Pressure shell and seat pneumatic (with N2) testing shall be submerged in water.

6

7

8 This Data Sheet shall be read in conjunction with Specification for Valves (PTS/GTS).

9 The Charpy V-notch test shall be conducted at below temperatures, Test procedure shall conform to ASTM A 370For CS : at -20 0C Energy Absorbed Min. 28J & Avg. 35J

10

23.04.2019

DATE

All butt welded valves shall have pup pieces, as per the PMS, datasheet and below details :Thickness of pup piece shall be determined by the vendor as per code requirements. The pipe end of the pupPiece shall match the connecting pipe. The connecting pipe details shall be taken as mentioned in the valve data sheet. - NA

At 90 barg (As per API 6D Cl. H4.1 & 4.2(Note 5)

MK Issued for RFPNC00

3 Opening / Closing (with operator mountedon the valve)

5 mins.

All test certificates including, Physical (Tensile & Impact), Chemical, NDT, Testing, Painting etc.

DESCRIPTION

Vendor to confirm the suitability of material for specified pressure-temperature rating.

Vendor shall submit cross sectional drawing, catalogues showing the material of construction for each component of the valve as a part of offer.

PREPARED BY

* Manufacturer/ Supplier/ Vendor to indicate

CHECKED BY

Page 2 of 2

VISUAL AND DIMENSIONALEXAMINATION TEST

DATA SHEET No. 6C1

TEST

15 mins.

DATA SHEETBALL VALVES ( 2" SIZE )

P.013828 D 11088 002

For LTCS : at -20 0C Energy Absorbed Min. 28J & Avg. 35Jand at temperature specified in Material Spec. or -45 0C, whichever is lower. Energy Absorbed as per Material Spec.

5 mins.

Pneumatic Test (With Nitrogen) Shell& seat

5 mins.

5 mins.

SKH

APPROVED BY

All pressure retaining and pressure controlling parts of valves shall be supplied with en 10204 - 3.2 certificates.

REV


I GENERAL- VALVE MANUFACTURER -- ACTUATOR MANUFACTURER NA


III. CONNECTING PIPE DETAILS 2 " OD

- MATERIAL ASTM A333 GR. 6

- DIAMETER (OD)

- THICKNESS Sch. 160

IV. VALVE CONSTRUCTION DESIGN :- APPLICABLE SPECIFICATION PTS - PIPELINE VALVES (P.013828 D 11077 209) & GTS 70000/740/GTS/402 Rev. 07- CONSTRUCTION DESIGN API 6D- PIPE CLASS 6C1- RATING 600 #- INSTALLATION ABOVE GROUND- VALVE BORE FULL BORE- VALVE BODY FULLY WELDED/ BOLTED- TYPE TRUNNIOUN MOUNTED DOUBLE BLOCK & BLEED- VALVE OPERATION WRENCHED OPERATED- END CONNECTION BW (As per ANSI 16.25)

V VALVE MATERIAL SPECIFICATIONPART DESCRIPTION

- BODY MATERIAL

- BALL MATERIAL

-

- SEAT SEAL

- STEM (No Casting)

- STEM SEALS- Primary seat- Secondary Seat- ANTI-BLOW OUT- LENGTH OF EXTENSION STEM

- PUPS (Applicable only for BW end)Length :Material of ConstructionThickness

- PAINTINGSurface preparation

Primer

Finish- INSULATION NO

REV CHECK BY APPR BY

00 MS SKH

PREP BY

60.3 mm

DATA SHEET No. 6C1

*

Refer above mentioned "Connecting Pipe Detail"

SPECIFIED MATERIAL

RPTFE / DEVLON or equivalent

ASTM A 182 Gr. F316 OR ASTM A351 Gr. CF8M OR (ASTM A350 GR. LF2 CL1 /ASTM A 352 GR.LCC + ENP)

*

VITON / DEVLON or equivalent

PTFE / VITON or equivalent

*


Issued for RFP

*YES

Metal to Metal

DESCRIPTION

Not Applicable

P.013828 D 11088 004

- 45 to 65

Page 1 of 2

BODY SEAT RINGS (No Casting) AISI 4140 with 75 micron ENP COATING / AISI 410

DATA SHEETFOR

BALL VALVES ( 2" SIZE)

*

At least 2.0 D

Type of paint, Total DFT shall be as per paint system no. chosen from Table A5, ISO 12944-5 suitable for highly corrosive environment. Final shade of valve shall be as perPainting Specification No. P.013828 D 11077 207.Final Paint DFT - 320 Microns minimum

Suitable to Connecting pipe material in terms of strength and thickness.

23.04.2019

DATE

MK

*

SA 2.5

ASTM A350 GR. LF2 CL.1 / ASTM A352 GR. LCC

2 mm

92

**

*

To suit welding with valve & pipe as per ASME B 31.8

OFFERED MATERIAL


VI.

- HYDROSTATIC SHELL TESTTest pressure : 1.5 x Design Pressure Test Duration :

- HYDROSTATIC SEAT TESTTest pressure : 1.1 x Design Pressure Test Duration :

- PNEUMATIC SEAT & SHELL TEST

Test Duration

- AIR SEAT TEST : 7 Bar(g) Test Duration

- FUNCTIONAL TEST

Test pressure : At 90 barg Test Duration

- HELIUM TEST : 25% of Rated pressure Test Duration : 30 mins.(As per ASME Secv , Subsection A, Article 10 , Appendix IV)

- LEAK TEST : API 598

- DOUBLE BLOCK & BLEED TEST : Yes

- TORQUE TEST : API 6D

- ANTISTATIC TEST : BS - 5351 / API 598

- FIRE TEST : API 6FA

- : MSS-SP-55

VII QUALITY CONTROL



NOTES:-1 Stem height will be finalised/decided during detail engineering, If applicable

2 Unless otherwise stated, all tests will be witnessed by the TPIA

3


5 High Pressure shell and seat pneumatic (with N2) testing shall be submerged in water.

6

7

8 This Data Sheet shall be read in conjunction with Specification for Valves (PTS/GTS).

9 The Charpy V-notch test shall be conducted at below temperatures, Test procedure shall conform to ASTM A 370For CS : at -20 0C Energy Absorbed Min. 28J & Avg. 35J

10

23.04.2019

DATE

All butt welded valves shall have pup pieces, as per the PMS, datasheet and below details :Thickness of pup piece shall be determined by the vendor as per code requirements. The pipe end of the pupPiece shall match the connecting pipe. The connecting pipe details shall be taken as mentioned in the valve data sheet.

At 90 barg (As per API 6D Cl. H4.1 & 4.2(Note 5)

MK Issued for RFPMS00

3 Opening / Closing (with operator mountedon the valve)

5 mins.


DESCRIPTION

Vendor to confirm the suitability of material for specified pressure-temperature rating.

Vendor shall submit cross sectional drawing, catalogues showing the material of construction for each component of the valve as a part of offer.

PREPARED BY

* Manufacturer/ Supplier/ Vendor to indicate

CHECKED BY

Page 2 of 2

VISUAL AND DIMENSIONALEXAMINATION TEST

DATA SHEET No. 6C1

TEST

15 mins.

DATA SHEETBALL VALVES ( 2" SIZE ) P.013828 D 11088 004


5 mins.

Pneumatic Test (With Nitrogen) Shell& seat

5 mins.

5 mins.

SKH

APPROVED BY


REV


I GENERAL- VALVE DETAILS



- MATERIAL ASTM A333 GR. 6- DIAMETER (OD)- THICKNESS Sch. 160

IV. VALVE CONSTRUCTION DESIGN :- APPLICABLE SPECIFICATION PTS no. P.013828 D 11077 209- CONSTRUCTION DESIGN ASME B.16.34 & BS 1873- PIPE CLASS 6C1

- RATING 600 #- INSTALLATION ABOVE GROUND- TYPE HIGH RESISTANCE TO VIBRATIONS AND TO HIGH DIFFERENTIAL PRESSURE- OPENING BILINEAR OR EQUAL PERCENTAGE- SEAT PARABOLIC DISC / BI DIRECTIONAL- GLAND TYPE BOLTED BONNET - NON ROTATING STEM- PATTERN STRAIGHT THROUGH GLOBE- VALVE OPERATION HANDWHEEL OPERATED- END CONNECTION RF (as per ANSI B 16.5)- FACE FINISH (Flanged End) 125 AARH SMOOTH FINISH


- BODY MATERIAL ASTM A350 GR. LF2 CL.1 / ASTM A352 GR. LCC

- DISC /RING MATERIAL

-- STEM- TRIM- GASKET & PACKING- BOLTS / NUTS- LENGTH OF EXTENSION STEM

- PUPS (Applicable only for BW end)Length :

Material of Construction- PAINTING

Surface preparation

Primer

Finish

- INSULATION NO


00 MS SKH

ASTM A320 Gr. L7 / ASTM A194-Gr.4 & 7 or superior *

PREP BY

MK

*

*

13% CR. STEEL (NO CASTING)

Type of paint, total DFT shall be as per paint system no. chosen from Table A5, ISO 12944-5 suitable for highly corrosive environment. FinalShade of valve shall be as per Painting Specification No. P.013828 D 11077 207.Final Paint DFT - 320 Microns (minimum)

Not Applicable

Spiral Wound AISI 304, Filling pure GRAPHITE, Centering RingCS

NA

*

*

DESCRIPTION

OFFERED MATERIAL

SEAT ASTM A350 LF2 + STELLITED

(ASTM A350 GR. LF2, CL1/ ASTM A 352 GR.LCC) with 13% CRSTEEL FACING

60.3 mm

DATA SHEETDATA SHEETFOR

GLOBE VALVES ( 2" SIZE)P.013828 D 11088 005

- 45 to 65

Page 1 of 2

Issued for RFP23.04.2019

DATE

NANA

SA 2.5

2 mm

92

ASTM A 182 F6

*

*

SPECIFIED MATERIAL

Rev-0 Laying and Associated Works For HMEL Connectivity Pipeline Project Page 1 of Pages)

III. TEST

- HYDRAULIC SHELL TEST : See BS-1873 & PTS (Test duration minimum 15 min)- HYDRAULIC SEAT TEST : See BS-1873 & PTS (Test duration minimum 30 min)- HYDRAULIC BACK SEAT TEST : See BS-1873 & PTS (Test duration minimum 30 min)- PNEUMATIC SHELL & SEAT TEST : See BS-1873 & PTS (Test duration minimum 5 min at 7 Bar with Nitrogen)- AIR SEAT TEST : See BS-1873 & PTS (Test duration minimum 5 min)- HELIUM LEAK TEST : See BS-1873 & PTS (Test duration minimum 30 min)- HIGH PRESSURE SHELL TEST : See BS-1873 & PTS- TORQUE TEST : See BS-1873 & PTS- LOW PRESSURE CLOSURE TEST : See BS-1873 & PTS- HIGH PRESSURE CLOSURE TEST : See BS-1873 & PTS- FUNCTIONAL TEST : See BS-1873 & PTS- CYCLIC PRESSURE TEST - : See BS-1873 & PTS (10 Open - Close - Open cycles with Maximum diffrential pressure)

- 1 Valve per size- VISUAL EXAMINATION : See BS-1873 / MSS-SP-55 & PTS- DIMENSIONAL EXAMINATION See APPR. DRG./ BS-1873 / ASME B16.10 / ASME B16.5/ B16.25/ API 6D & PTS- FIRE SAFE TEST (Type Test) : API 6FA / API 607 / BS 5146 / OCMA

- (Certificates of previously conducted tests shall be submitted)

VII QUALITY CONTROL



NOTES:-1 Unless otherwise stated, all tests shall be witnessed by the TPIA.


3 Vendor to confirm the suitability of material for specified pressure-temperature rating.

4 Vendor shall submit cross sectional drawing, catalogue showing the material of construction for each component of the valve as a part of offer.

5 For Inspection & Testing tender QAP no. P.011947 M 11000 037 shall be reffered.

6 Offered Valves shall comply following requirements :

a) Seat shall be non-renewable integral type only.

b) Valves shall be suitable for Horizontal/Vertical installation.

c) Direction of valve shall be indicated on each valve.7 The Charpy V-notch test shall be conducted at below temperatures, Test procedure shall conform to ASTM A 370

For CS : at -20 0C Energy Absorbed Min. 28J & Avg. 35J

SKH23.04.2019

DATE CHECKED BYPREPARED BY

Issued for RFPMS

Page 2 of 2

DATA SHEET No. 6C1DATA SHEET

GLOBE VALVES ( 2" SIZE ) P.013828 D 11088 005

APPROVED BY

MK00



REV


DESCRIPTION


I. PROCESS DATA- FLUID : Natural Gas- FLUID SYMBOL : NG

- DESIGN CONDITION :TEMPERATURE (°C)

- PRESSURE (Barg)

II. VALVE DATA- APPLICABLE SPECIFICATION :- CONSTRUCTION DESIGN : API 6D- DIMENSIONAL STANDARD : ANSI B 16.10- PIPE CLASS :- RATING :

- TYPE :- END CONNECTION :

- BODY MATERIAL :

- WEDGE : ASTM A350-LF2 OR ASTM A 182 F6- DISC / RING : ASTM A350 LF2 / ASTM A 352 GR. LCC +13 %CR. STEEL (NO CASTING)- HINGE PIN : ASTM A 182 F6/ 13 %CR. STEEL (NO CASTING)- GASKET : GRAPHITE- PUPS (Applicable only for BW end) :

LENGTH At least 2.0 D for size below 6” & 300 mm for 6” and above size valves.MATERIAL OF CONSTRUCTION Suitable to Connecting pipe material in terms of strength and thickness.

- PAINTINGSurface preparation :Primer :

Finish :

- INSULATION : NO

APPROVED

SKH

CORROSION ALLOWANCE : 2 mm

BUTT WELDED (BW)

ANSI B 16.25

600#

6C1

- 45 to 65

6C1

MK MS

SA 2.5

ASTM A350 LF2 / ASTM 352 Gr. LCB

A/G

ANSI B 16.5, 125 AARH SMOOTH FINISH

DESCRIPTION

Type of paint, DFT and total DFT shall be as per paint system no.chosen from Table A5, ISO 12944-5 suitable for highly corrosiveenvironment. Final shade of valve shall be as per attached paintingtable.Final Paint DFT - 320 Microns minimum. Final shade of valve shall beas per Painting Specification No. P.013828 D 11077 207.

SWING CHECK

CHECKED

92

A/G

FLANGED (RF)

Issued for RFP

Upto 2"

DATA SHEETCHECK VALVES (NRV)

23.04.2019DATE REV

00PREPARED

Page 1 of 2

DATA SHEET No.

P.013828 D 11088 006

Rev-0 Laying and Associated Works For HMEL Connectivity Pipeline Project Page Page} of Pages}

III. TEST- HYDROSTATIC SHELL TEST :

Test pressure : 1.5 x Design Pressure- HYDROSTATIC SEAT TEST : : 1.1 x Design Pressure- AIR SEAT TEST : 6 Barg- HIGH PRESSURE CLOSURE TEST : API 598- LOW PRESSURE CLOSURE TEST : API 598- LEAK TEST : API 598- FIRE SAFE TEST : API 6FA / API 6FD- VISUAL & DIMENSIONAL EXAMINATION : YES

IV QUALITY CONTROL

- MATERIAL CERTIFICATES

- ALL TEST CERTIFICATES

IIV VALVE DETAILS

NOTES:-

1 Unless otherwise stated, all tests will be witnessed by the purchaser/control authority.2 MR shall contain following information as minimum: Size, Rating, Operator, Location, End Connection etc.3 Vendor to confirm the suitability of material for specified pressure-temperature rating.4 Vendor shall submit cross sectional drawing, catalogue showing the material of construction for each component of the valve as a part of offer.5 Offered Valves shall comply following requirements :a) Seat shall be non-renewable integral type only.b) Valves shall be suitable for Horizontal/Vertical installation flow upwardc) Direction of valve shall be indicated on each valve.

DATE

DATA SHEETCHECK VALVES (NRV)

Issued for RFP

ALL PRESSURE RETAINING AND PRESSURE CONTROLLING PARTS OF VALVES SHALL BESUPPLIED WITH EN 10204 - 3.2 CERTIFICATES.ALL TEST CERTIFICATES INCLUDING, PHYSICAL (TENSILE & IMPACT), CHEMICAL, NDT,TESTING , PAINTING ETC.

23.04.2019 00 MK

CHKECKEDPREPARED APPROVED DESCRIPTION

NC SK

REV

DATA SHEET No.

P.013828 D 11088 006

Page 2 of 2

Rev-0 Laying and Associated Works For HMEL Connectivity Pipeline Project Page Page} of Pages}

I GENERAL



- MATERIAL ASTM A333 GR. 6- DIAMETER (OD)- THICKNESS Sch. 160

IV. VALVE CONSTRUCTION DESIGN :- APPLICABLE SPECIFICATION PTS no. P.013828 D 11077 209- CONSTRUCTION DESIGN ASME B.16.34 & BS 1873- PIPE CLASS 6C1

- RATING 600 #- INSTALLATION UNDER GROUND- TYPE HIGH RESISTANCE TO VIBRATIONS AND TO HIGH DIFFERENTIAL PRESSURE- OPENING BILINEAR OR EQUAL PERCENTAGE- SEAT PARABOLIC DISC / BI DIRECTIONAL- GLAND TYPE BOLTED BONNET - NON ROTATING STEM- PATTERN STRAIGHT THROUGH GLOBE- VALVE OPERATION HANDWHEEL OPERATED- END CONNECTION BE (as per ANSI B 16.5)


- BODY MATERIAL ASTM A350 GR. LF2 CL.1 / ASTM A352 GR. LCC

- DISC /RING MATERIAL

-- STEM- TRIM

- GASKET & PACKING

- BOLTS / NUTS- LENGTH OF EXTENSION STEM

- PUPS (Applicable only for BW end)Length :

Material of Construction

Thickness

- PAINTINGSurface preparation

Primer

Finish

- INSULATION NO


00 MS SKH

ASTM A320 Gr. L7 / ASTM A194-Gr.4 & 7 or superior *

To suit welding with valve & pipe as per ASME B 31.8

PREP BY

MK

*

*

13% CR. STEEL (NO CASTING)

Type of paint, total DFT shall be as per paint system no. chosen from Table A5, ISO 12944-5 suitable for highly corrosive environment. FinalShade of valve shall be as per Painting Specification No. P.013828 D 11077 207.Final Paint DFT - 320 Microns (minimum)

3.5m Max. Please see note 8

Spiral Wound AISI 304, Filling pure GRAPHITE, Centering RingCS

Refer above mentioned "Connecting Pipe Detail"

*

*

DESCRIPTION

OFFERED MATERIAL

SEAT ASTM A350 LF2 + STELLITED

(ASTM A350 GR. LF2, CL1/ ASTM A 352 GR.LCC) with 13% CRSTEEL FACING

60.3 mm

DATA SHEETDATA SHEETFOR

GLOBE VALVES ( 2" SIZE)P.013828 D 11088 008

- 45 to 65

Page 1 of 2

Issued for RFP23.04.2019

DATE

At least 2.0 DSuitable to Connecting pipe material in terms of strength andthickness.

SA 2.5

2 mm

92

ASTM A 182 F6

*

*

SPECIFIED MATERIAL


III. TEST

- HYDRAULIC SHELL TEST : See BS-1873 & PTS (Test duration minimum 15 min)- HYDRAULIC SEAT TEST : See BS-1873 & PTS (Test duration minimum 30 min)- HYDRAULIC BACK SEAT TEST : See BS-1873 & PTS (Test duration minimum 30 min)- PNEUMATIC SHELL & SEAT TEST : See BS-1873 & PTS (Test duration minimum 5 min at 7 Bar with Nitrogen)- AIR SEAT TEST : See BS-1873 & PTS (Test duration minimum 5 min)- HELIUM LEAK TEST : See BS-1873 & PTS (Test duration minimum 30 min)- HIGH PRESSURE SHELL TEST : See BS-1873 & PTS- TORQUE TEST : See BS-1873 & PTS- LOW PRESSURE CLOSURE TEST : See BS-1873 & PTS- HIGH PRESSURE CLOSURE TEST : See BS-1873 & PTS- FUNCTIONAL TEST : See BS-1873 & PTS- CYCLIC PRESSURE TEST - : See BS-1873 & PTS (10 Open - Close - Open cycles with Maximum diffrential pressure)

- 1 Valve per size- VISUAL EXAMINATION : See BS-1873 / MSS-SP-55 & PTS- DIMENSIONAL EXAMINATION See APPR. DRG./ BS-1873 / ASME B16.10 / ASME B16.5/ B16.25/ API 6D & PTS- FIRE SAFE TEST (Type Test) : API 6FA / API 607 / BS 5146 / OCMA

- (Certificates of previously conducted tests shall be submitted)

VII QUALITY CONTROL



NOTES:-1 Unless otherwise stated, all tests shall be witnessed by the TPIA.


3 Vendor to confirm the suitability of material for specified pressure-temperature rating.

4 Vendor shall submit cross sectional drawing, catalogue showing the material of construction for each component of the valve as a part of offer.

5 For Inspection & Testing tender shall be done as per approved QAP

6 Offered Valves shall comply following requirements :

a) Seat shall be non-renewable integral type only.

b) Valves shall be suitable for Horizontal/Vertical installation.

c) Direction of valve shall be indicated on each valve.7 The Charpy V-notch test shall be conducted at below temperatures, Test procedure shall conform to ASTM A 370

For CS : at -20 0C Energy Absorbed Min. 28J & Avg. 35J

8 Stem height will be finalised/decided during detail engineering

SK23.04.2019

DATE CHECKED BYPREPARED BY

Issued for RFPNC

Page 2 of 2

DATA SHEET No. 6C1DATA SHEET

GLOBE VALVES ( 2" SIZE ) P.013828 D 11088 008

APPROVED BY

MK00



REV


DESCRIPTION


Date: 22.04.2019 Revision: 00Prepared : MKChecked : RP /SGApproved : NC / SKH

GTS / PTS

chap. Manufacturer TPIA (By EPC Contractor) Client / Consultant

3 specification Perform review point review point6.1. specification Perform review point review point6.1. specification Perform review point review point

6.1. / 6.2.2. specification Perform hold point hold point

6.2.8. ASME B16.34 specification, Perform hold point hold point

6.3 specification, Data Sheet Perform review point review point

8.1, 8.2, 10.2 specification Perform review point review point

8.3 specification Perform review point review point8.5 specification Perform review point review point

8.6.6 specification Perform review point review point

11 specification Perform review point review point

GTS / PTS certif. 3.2 Perform hold point review point


- For CS at -200C Energy is35J/cm²(Avg.), 28J/cm²(Ind.) - For LTCS at -200C Energy is35J/cm²(Avg.), 28J/cm²(Ind.)and Material Standard’s impact testtemperature requirements or -450C,Whichever is lower.

certif. 3.2 Perform hold point review point

- ASME B 16.34, App IV ASME B 16.34, App IV certif. 3.2 Perform witness point review point- ASME B 16.34 ASME B 16.34 certif. 3.2 Perform review point review point

- ASME B 16.34 ASME B 16.34 certif. 3.2 Perform witness point review point



1A

Mechanical tests ( YS, TS, % EL, Ys / TS ratio, Micro /Macro, hardness etc)(Remark : marking transfer by TPIA)

-

- heat treatment procedure

Sl.Nos.

- calculation of body bolting, Bonnet, Cover (For PressureRetaining Parts)

ACTIVITY

- pressure test procedure

1

CONTROL BEFORE MANUFACTURING

- material part list- dimensional drawings

Document type

- list of operation in manufacturing and control

- calculation butt welding ends

Acceptance criteriaApplied standard e/oProcedure

- qualified welding procedures/welders performancesqualification record

Scope of Inspection

- non destructive testing procedures

- painting procedure

Chemical Testing, Carbon Equivalent

Wet magnetic Particle Examination (100% External &accessible Internal)

Charpy-test at -20°C and as per Material requirement2 test sets (1 long./1 trans)(Remark : marking transfer by TPIA)

UT of Forging Body (100%)Radiography Test of Casting Body (100%)

FLANGES:

QAP No. : P.013828 D 11013 201

QUALITY ASSUARANCE PLAN BALL VALVES (Upto 18" Size)

CONTROL ON RECEIPT OF MATERIAL

- Fixation of Operation Methodology

Valve BODY:


7


LAYING AND ASSOCIATED WORKS FOR HMEL CONNECTIVITY PIPELINE PROJECT Page 1 of 5


GTS / PTS


Sl.Nos. ACTIVITY

1


Document typeAcceptance criteriaApplied standard e/oProcedure

Scope of Inspection

QAP No. : P.013828 D 11013 201




- ASME B 16.34, App IV ASME B 16.34, App IV certif. 3.2 Perform witness point review point

- ASME B 16.34 ASME B 16.34 certif. 3.2 Perform review point review point

ASME B 16.34 ASME B 16.34 certif. 3.2 Perform witness point review point





- ASME B 16.34, App IV ASME B 16.34, App IV certif. 3.2 Perform witness point review point- ASME B 16.34 ASME B 16.34 certif. 3.2 Perform review point review point

- ASME B 16.34 ASME B 16.34 certif. 3.2 Perform witness point review point

- at -20°C, for Base/Weld/HAZ -35J/cm²(Avg.), 28J/cm²(Ind.). - at 0°C, for Base - 100J/cm²(Avg.),80J/cm²(Ind.),- at 0°C, for Weld/HAZ - 40J/cm²(Avg.),32J/cm²(Ind.)


GTS / PTS certif. 3.2 Perform hold point RW

GTS / PTS certif. 3.2 Perform hold point RW

1A

Perform

Charpy-test at -20°C and as per Material requirement2 test sets (1 long./1 trans.)(Remark : marking transfer by TPIA)

BALL / OBTURATOR (Note -7):

Chemical Test, Carbon Equivalent

7

-



Mechanical tests(Remark : marking transfer by TPIA)

EXTENSION PIPE PIECES AS PER DATA SHEET




UT of Forging Body (100%)

Radiography Test of Casting Body (100%)

UT of Forging Body (100%)Radiography Test of Casting Body (100%)



7

7

certif. 3.2 hold point review point

LATERAL CONNECTIONS:

- Mechanical tests ( YS, TS, % EL, Ys / TS ratio, Micro /Macro, hardness etc)(Remark : marking transfer by TPIA)

GTS / PTS



GTS / PTS


Sl.Nos. ACTIVITY

1



Scope of Inspection

QAP No. : P.013828 D 11013 201


GTS / PTS

GTS / PTS

GTS / PTS certif. 3.1 Perform review point review point


GTS / PTSGTS / PTS certif. 3.1 Perform review point review point


GTS / PTSGTS / PTSGTS / PTSGTS / PTSGTS / PTSGTS / PTSGTS / PTSGTS / PTS

GTS / PTS

GTS / PTSGTS / PTS

Perform

Perform

Perform

Perform

Perform

Perform review point

STUDS/NUTS (With Xylan Coating)

- Mechanical and Chemical tests

- Mechanical tests ( YS, TS, % EL, Ys / TS ratio, Micro /Macro, hardness etc)(Remark : marking transfer by TPIA)

SEAT:

-Mechanical tests ( YS, TS, % EL, Ys / TS ratio, Micro /Macro, hardness etc)(Remark : marking transfer by TPIA)

review point

hold point (Mech.)review(Others) review pointcertif. 3.17

7

7

7

7

certif. 3.1

DRAIN: OPEN BLOCK VALVE AT DRAIN TAP:

- Chemical Test, Mechanical tests

7

certif. 3.1

certif. 3.1

hold point (Mech.)review(Others)

STEM:

hold point (Mech.)review(Others)

review point

review pointcertif. 3.1

OTHER VALVE PARTS INCLUDING PIPE PUPPIECE

7

hold point (Mech.)review(Others)- 'Chemical Test, Mechanical tests

certif. 3.1 hold point (Mech.)review(Others)7

- 'Chemical test, mechanical testsDRAIN: UPPER BALL VALVE & NEEDLE VALVE:

STEM & SEAT SEALING CONNECTION :

-Chemical Testing, Carbon Equivalent

-Chemical Testing, Carbon equivalent

- Mechanical tests ( YS, TS, % EL, Ys / TS ratio, Micro /Macro, hardness etc)(Remark : marking transfer by TPIA),- Chemical tests, Carbon equivalent

VENT/BLEED PLUG:- 'Chemical test,''Mechanical tests

review point

review point



GTS / PTS


Sl.Nos. ACTIVITY

1



Scope of Inspection

QAP No. : P.013828 D 11013 201


8.1 - 8.2 ASME IX + spec. ASME IX + spec. Welding ProcedureSpecification (WPS) Perform hold point review & approval point

8.3 ASME VIII Div.1 ASME VIII Div.1 review CTT/TT curves Perform review report review report

8.4.1 ASTM A370 GTS / PTS certif. 3.2 Perform hold point review point

8.4.2 ISO 148 or ASTM A370



8.5.1 ASME SECT V art. 2 ASME SECT. VIII, div.1, UW 51. (RT-Test report) Perform witness point review point

8.5.1 ASME SECT V art. 5 ASME SECT. VIII, div.1, App.12 UT-Test report Perform witness point review point

8.5.1 MSS-SP-54 (RT-Test report) Perform witness point review point

8.5.1 ASME SECT V art. 5 ASME SECT. VIII, dic.1, App.12 UT-Test report Perform witness point review point

8.5.1 ASME SECT V art. 7 ASME SECT. VIII App.6 MPE-Test report Perform witness point review point

8.5.1 Sec 8 proc.7 MSS-SP-55 report Perform hold point review point

8.5.1 Sec 8 proc.24 DWG ** report Perform witness point review point

Finished bevel end pipe used for field welding :

8.5.1 ASME SECT V art. 7ASME SECT V art. 6

unacceptable defects : defects not parallelto the surface extending into the bevel +defect extending into the bevel providedthe lamination is parallel to the surfaceand has a transverse dimension exceeding6.35 mm

MPE/ LPE-Test report Perform witness point review point

8.5.1 ASME SECT V art. 5 ASME SECT. VIII, div.1, App.12 UT-Test report Perform witness point review point8.5.1 ASME SECT V art. 2 ASME SECT. VIII, div.1, UW 51. RT-Film & report Perform witness point review point8.5.1 Sec 8 proc.7 MSS-SP-55 +DWG** report Perform witness point review point

8.6.2 API 6D + GTS / PTS @ 1.5 x Design Pr.,30 Min(NPS>18") / 15 Min(NPS<16"). certif. 3.2 Perform witness point hold point

8.6.3 API 6D + GTS / PTS @ 1.1 x Design Pr., 5 Min. certif. 3.2 Perform witness point hold point

8.6.5 GTS / PTS @ 95 barg for 5 min. certif. 3.2 Perform witness point hold point

8.6.4 GTS / PTS @ 6 bar certif. 3.2 Perform witness point hold point

8.6.5 GTS / PTS @ 7 bar, 5 Min. certif. 3.2 Perform hold point hold point

External leak testing (with Soup suds)

UT inspection on 25 mm of base material

Welds and repair welds shall be performed according towritten qualified procedures

Mechanical tests(Remark : marking transfer by TPIA)


UT on 25 mm of base mat. (at each side) and eachweld(100%)

Magnetic Particule Examination / Liquid PenetrantExamination

3

FINAL INSPECTION TEST

2A

2

Pneumatic Test (with nitrogen) ( Shell & Seat)

Visual examination

Dimensional examination

Hydrostatic Shell Test

(if feasable) RT on butt welds

Magnetic Particule Examination on valve body10 % valves < 6"100% valves ≥ 6"

FABRICATION AND TESTS

Hydrostatic Seat Test

Air seat test

Visual and dimensional examination

(if not feasable & thk. > 15mm) UT on butt welds

RT examination on 25 mm of base material

Butt welding ends on cast bodies shall be examinedbefore fabrication welding end by radiography (Over awidth of 70 mm)(not applicable for forged bodies)

Heat treatment fully welded valve and test pieces



GTS / PTS


Sl.Nos. ACTIVITY

1



Scope of Inspection

QAP No. : P.013828 D 11013 201


x ASME Sec.V, Subsection A,Art.10, Appendix IV. @ 25% of Rated Pressure for 30 mins. certif. 3.2 Perform hold point hold point

x API 6D/API 598 + GTS / PTS API 6D/ API 598 certif. 3.2 Perform hold point hold point

x API 6D/API 598 + GTS / PTS API 6D/ API 599 certif. 3.3 Perform hold point hold point

x BS 5351 + GTS / PTS BS 5351 + specification certif. 3.2 Perform hold point hold point

8.7 API 6D report Perform witness point hold point8.8 API 6FA API6FA report Perform review report review report8.10 Sec 8 proc.7 MSS-SP-55 / GTS / PTS report Perform hold point review report

8.10 Sec 8 proc.24 DWG ** report Perform witness point review report9 section 9 of specification section 9 specification X Perform witness point review report

9.1.2 section 9 of specification section 9 specification X X X X10 section 10 of specification section 10 of specification certif. 3.2 Perform hold point review report11 SIS055900 SA2.5, Cl.11 of Specification report Perform witness point review report

RT: Radiographic test PT:Liquid penetrant test MT: Magnetic particle test TPIA: Third Party Inspection Agency; .

P: Performed R:Review W: Witness RW: Random Witness

Note: 12345678910111213

For All Forging Materials, The Specimen Shall Be Taken From The Integral Part of The Forging.The hold points in this QAP pertains to mechanical tests and hydro test. These tests on all the components can be clubbed together to be performed during a single visit of TPIAHeat treatment start and stop temperature chart shall be witnessed & signed by TPIA. Power failure log book / sheet shall be maintained

LEGENDS:

Certification requirements shall comply with European Standard EN 10204 (latest edition)In case of conflict between purchase specification, contract documents and QAP, more stringent conditions shall be applicable.

Marking

Operational torque testFire test

Helium Leak Test

TPIA shall ensure that Ball and Stem are Electroless Nickel Plated (ENP) with minimum thickness of 75 microns as per data sheet requirement.

Painting And Coating

Inspector's stampControl of all certificates

The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner/Owner's representative and TPIA.

Contractor in coordination with Supplier/Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organise Inspection.

Supplier shall submit Calibration certificates of all Instruments/Equipment to be used for Inspection and Testing to TPIA with relavant procedures and updated standards for TPIA reveiew/Approval.TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.TPIA shall also Review the Test certificates submitted by the Actuator manufacturer.

The above testing and acceptance critera are minimum requirements, however, equipment supplier shall ensure and that the product also comply to the additional requirements as per Technical specifications and data sheets.

Double Block and Bleed Test

Antistatic Test

3

Functional Test (10 Opening / Closing with Operatormounted on the valve at 95 barg)

Dimensional examination

Visual examination


Date: 22.04.2019 Revision: 00

Prepared : MK

Checked : RP /SG

Approved : NC / SKH

PTS

Clause No. Manufacturer TPIA (By EPC Contractor) Client / Consultant

0

- list of operation in manufacturing and control 9.1 specification Perform review point review point

- Fabrication and Control procedure 9.1 specification Perform review point review point

2.7 specification Perform review point review point

9.1; 2 and 3 specification Perform review point review point

9.2 ; 2 specification Perform review point review point

2, 4, 5, 6 & 7 specification Perform review point review point


As per Appl PTS specification Perform review point review point

1 BASE MATERIAL

1.1 MATERIALS

5.1.1 1 per heat PTS certif. 3.2 Perform hold point review report

5.1.2 1 per heat Mat. Spec. certif. 3.2 Perform hold point review report

1.2 CHEMICAL COMPOSITION review report

3.10 1 per heat PTS-Table1+ ASTM & Mat. Spec. Lab cer Perform review report review report

2 FABRICATION & TESTS 4

- report Perform hold point review report

- Review of welders records report Perform hold point review report

- Cosumable Verification ASME SEC IX / SEC IIC PTS & ASME Sec-IX & Sec-II report Perform review point

2.2 4.3 all fittings T/T Graph PTS certif. 3.2 Perform Witness Point (Loading &Unloading)

review report

- time temperature chart 4.3.1 1 per furnace charge report Perform review report review report

- micrographic examination 4.3.2 1 per lot* ASTM E 112 Grain size : range 8 to 12 certif. 3.2 Perform hold point review report

QUALITY ASSURANCE PLANFITTINGS

Scope of Inspection

QAP No. : P.013828 D 11013 202

2.1

Applicable standard &Procedure Acceptance criteria Document typeS NO.



- dimensional drawings

Frequency

Welding

Review of WPS (If New WPS has established, same to be witnessedby TPIA) 4.1 & 4.2

Heat treatment (Loading & Unloading shall be witnessed by TPIA, Powerfailure log shall be maintained)

ACTIVITY


- material part list

PTS & ASME Sec-IX


Tensile tests (YS, UTS, YS/UTS, %EL, RA, Bend etc. as applicable)(remark : marking transfer by TPIA)

Charpy-test at as per Mat. Spec. (Impact Energy & Shear Area)(remark : marking transfer by TPIA)

- Design Proof test

Check chemical analysis & Carbon Equivalent

ASME SEC IX



Prepared : MK

Checked : RP /SG

Approved : NC / SKH

PTS



Scope of Inspection

QAP No. : P.013828 D 11013 202

Applicable standard &Procedure Acceptance criteria Document typeS NO. FrequencyACTIVITY

CONTROL BEFORE MANUFACTURING2.3

-

- base material 1 per lot PTS + E/R <= 0.85 & Mat. Spec.

- weld 1 per lot PTS & Mat. Spec.

-

- base material (Longitudinal & Transverse) 2 sets of 3 specimens perlot

- weld (Transverse) 1 sets of 3 specimens perlot

- HAZ (Transverse) 1 sets of 3 specimens perlot

- Flattening test for fitting < 2" 5.1.3 1 per group (*) PTS PTS & Mat. Spec.

2.4 Chemical analysis & Carbon Equivalent 5.2 For each lot ASTM & PTS Cl 3.10.1 & 3.10. 2 PTS & Mat. Spec. certif. 3.2 Perform review report review report

3 NON DESTRUCTIVE EXAMINATIONS (NDE) 5.3

Longitudinal welds : ASME sectionVIII division 1 UW 51

Girth welds : API 1104 section 6.0

3.2 Ultrasonic inspection

- base material thickness ≥ 6 mm 6.1.2.1, 6.1.2.2,6.1.2.4 , 6.1.3.3 100% ASME section V art 23, SA-388 ASME section VIII division1 UF-55

- weld 6.1.2.1, , 6.1.2.2,6.1.3.3, 100% ASME V ASME section VIII division1,

appendix 12

3.3 - Magnetic particle inspection 6.1.2.1, 6.1.2.4,6.1.3.2, 6.1.3.5, 100% ASME V ASME section VIII division1,

appendix 6certif. 3.2 Perform witness point review report

3.4 - After machining

- Magnetic particle or liquid penetrant of the bevels 6.1.2.4, 6.1.3.5, wall thickness ≥ 6 mm allfinished bevels ASME V PTS & Mat. Spec.

- Ultrasonic inspection of 25 mm of base material (if t ≥ 6 mm) 6.1.2.1, 6.1.2.2,6.1.2.4 , 6.1.3.3 All finished bevels ASME V PTS & Mat. Spec.

3.5 - Visual examination 6.1.2.3 & 6.1.3.1 100% PTS & Mat. Spec. certif. 3.2 Perform hold point review report

10% NPS ≤ 6"

100% NPS > 6"Perform

Perform

Perform

Perform

Perform

Tension test for fitting ≥ 2" (YS, UTS, YS/UTS, %EL, RA, Bendetc. as applicable)

3.6 PTS & Mat. Spec. certif. 3.2 witness point review report

certif. 3.2

certif. 3.2 witness point review report

- Dimensionnal examination 6.1.2.5

witness point review report

certif. 3.2 witness point review report

4.2.4 & 5.1.1

hold point review report

3.1 Radiographic examination 6.1.1 and 6.1.3.4 All butt welds ASME section V

Mechanical testing(remark : marking transfer by TPIA)

certif. 3.2Impact test for fitting ≥ 2"

ASTM A 370

ISO 148 - Charpy V - Notch

- For CS at -20°C Energy is35J/cm²(Avg.), 28J/cm²(Ind.) - For LTCS at -20°C Energy is35J/cm²(Avg.), 28J/cm²(Ind.)and Material Standard’s impact testtemperature requirements or -450C,Whichever is lower.

4.2.4 & 5.1.2



Prepared : MK

Checked : RP /SG

Approved : NC / SKH

PTS



Scope of Inspection

QAP No. : P.013828 D 11013 202

Applicable standard &Procedure Acceptance criteria Document typeS NO. FrequencyACTIVITY

CONTROL BEFORE MANUFACTURING4 FINAL INSPECTION TEST

4.1 Marking 8 all certif. 3.2 Perform witness point reiew report

4.2 8.1.1 all certif. 3.2 Perform witness point reiew report

4.3 Documentation 9 - PTS & P.O. PTS & P.O. certif. 3.2 Perform hold point review report

(*) Fittings from the same heat of steel of the same shape and the same main pipe/plate dimension of the fittings

LOT - A lot consists of all fittings from one heat of steel with same initial wall thickness, from the same furnace charge for final heat treatment, from the same shape and the same main pipe/plate dimension.

LEGEND:

RT : Radiographic test PT : Liquid penetrant test MT : Magnetic particle test HT : Heat treatment VT : Visual test P : Performed

R : Review W : Witness TPIA : Third Party Inspection Agency;

Note: 1

2 The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner/Owner's representative and TPIA for each sizes.

3

4

5

6

78910 In case of conflict between purchase specification, contract documents and QAP, more stringent conditions shall be applicable.

Heat treatment start and stop temperature chart shall be witnessed & signed by TPIA. Power failure log book / sheet shall be maintainedFor All Forging Materials, The Specimen Shall Be Taken From The Integral Part of The Forging.

Certification requirements shall comply with European Standard EN 10204 (latest edition)- 3.2 Type.

TPIA along with Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.

Contractor shall in coordination with Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organise Inspection.

Inspector's stamp

The Above Testing and acceptance critera are minimum requirements, however, equipment supplier shall ensure that the product also comply to the additional requirements as per Technical specifications and data sheets.

Supplier shall submit Calibration certificates of all Instruments/Equipment to be used for Inspection and Testing to TPIA with relavant procedures and updated standards for TPIA reveiew/Approval.

TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.



Prepared : MK

Checked : RP /SG

Approved : NC / SKH

PTS

chap. Manufacturer TPIA (By EPCContractor) Client / Consultant

0

9.1 1 per purchase order specification Perform review point review point

- Fabrication and Control procedure 9.1 specification Perform review point review point

9.1; 2 and 3 specification Perform review point review point

9.2 ; 2 specification Perform review point review point

2, 4, 5, 6 & 7 specification Perform review point review point


As per PTS specification Perform review point review point

1 BASE MATERIAL

5.1.1 1 per lot* PTS / Mat. Spec. certif. 3.2 Perform hold point review report

5.1.2 1 per lot* (1 set of 3 specimenper temp. range) PTS / Mat. Spec. certif. 3.2 Perform hold point review report

CHEMICAL COMPOSITION

Check chemical analysis 3.10 1 per heat PTS-Table1 Perform review report review report

2 FABRICATION AND TESTS

2.1. 4.3 all fittings T/T Graph PTS certif. 3.2 Perform Witness Point (Loading& Unloading)

review report

- time temperature chart 4.3.1 1 per furnace charge report Perform review report review report

- micrographic examination 4.3.2 1 per lot* ASTM E 112 Grain size : range 8 to 12 certif. 3.2 Perform hold point review report

2.2. certif. 3.2 Perform hold point review report


Frequency

Mechanical tests(remark : marking transfer by TPIA)

Heat treatment (Loading & Unloading shall be witnessedby TPIA, Power failure log shall be maintained)

QAP No. : P.013828 D 11013 203

Mechanical tests(remark : marking transfer by TPIA)

- dimensional drawings

ACTIVITY


- list of operation in manufacturing and control

Charpy Impact test at temp. as per Mat. Spec.


QUALITY ASSURANCE PLANFLANGES

S.No.

- material part list

1.2

1.1

Applied standard e/oProcedure Acceptance criteria Document type

Tensile tests (YS, UTS, YS/UTS, %EL, RA, Bend etc. asapplicable)


Scope of Inspection



Prepared : MK

Checked : RP /SG

Approved : NC / SKH

PTS



Frequency

QAP No. : P.013828 D 11013 203

ACTIVITY


S.No. Applied standard e/oProcedure Acceptance criteria Document type

Scope of Inspection

2.2.1 - 4.2.4 & 5.1.1 1 sample per lot of HT perRaw material Heat

ASTM A 350 § 6.1.3 +E/R <= 0.85 / PTS PTS & Mat. Spec. certif. 3.2 Perform hold point review report

2.2.2 - 4.2.4 & 5.1.2 2 sets of 3 specimens per lot ofHT per RM Heat ISO 148 - Charpy V-Notch


certif. 3.2 Perform hold point review report

3 NON DESTRUCTIVE EXAMINATIONS (NDE)

3.1 Radiographic examination 6.1.1 and 6.1.3.4 All butt welds ASME Section-V Girth welds : API 1104 section 6.0 certif. 3.2 Perform witness point review report

3.2 Ultrasonic inspection 6.1.2.1, 6.1.2.2,6.1.2.4 , 6.1.3.3 100% ASME Section-V, Art-23,

SA-388 ASME section VIII division1 UF-55 certif. 3.2 Perform witness point review report

3.3 Magnetic particle inspection 6.1.2.1, 6.1.2.4,6.1.3.2, 6.1.3.5, 100% ASME Section-V ASME section VIII division1

appendix 6certif. 3.2 Perform witness point review report

After machining

- 6.1.2.4, 6.1.3.5, all finished bevels ASME Section-V PTS § 5.3.3.5. certif. 3.2 Perform witness point review report

- 6.1.2.1, 6.1.2.2,6.1.2.4 , 6.1.3.3

wall thickness ≥ 6 mm allfinished bevels ASME Section-V PTS § 5.3.3.5. certif. 3.2 Perform witness point review report

3.5 6.1.2.3 & 6.1.3.1 100% PTS certif. 3.2 Perform hold point review report

10% NPS ≤ 6"

100% NPS > 6"

Magnetic particle or liquid penetrant of the bevels

Ultrasonic inspection of 25 mm of base material

Visual examination

3.4

witness point review reportDimensionnal examination 6.1.2.5 Perform3.6

Charpy Impact test for flanges (Longitudinal &Transverse)

PTS certif. 3.2

Tension test for flanges (YS, UTS, YS/UTS,%EL, RA, Bend etc. as applicable)



Prepared : MK

Checked : RP /SG

Approved : NC / SKH

PTS



Frequency

QAP No. : P.013828 D 11013 203

ACTIVITY


S.No. Applied standard e/oProcedure Acceptance criteria Document type

Scope of Inspection

4 FINAL INSPECTION TEST

4.1 Marking 8 all Perform witness point review report4.2 Inspector's stamp 8.1.1 all certif. 3.2 Perform hold point review report4.3 Documentation 9 - PTS & P.O. PTS & P.O. certif. 3.2 Perform hold point review report

*

LEGEND:

RT : Radiographic test PT : Liquid penetrant test MT : Magnetic particle test HT : Heat treatment VT : Visual test RM : Raw Material

R : Review W : Witness P : Performed TPIA : Third Party Inspection Agency;

Note: 1

2

3

4

5

6

789

1011

The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner/Owner's representative and TPIA, for each size. Impact test at -20 deg C shall be conducted in addition to respective material requirement.

Certification requirements shall comply with European Standard EN 10204 (latest edition)-3.2 issued by TPIA and Vendor.



TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above. Owner reserves the right to inspect any quantity of item at any time during execution.


Contractor shall in coordination with Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organise Inspection.

LOT - A lot consists of all fittings from one heat of steel with same initial wall thickness, from the same furnace charge for final normalizing heat treatment, from the same shape and the same main pipe dimension.

Heat treatment start and stop temperature chart shall be witnessed & signed by TPIA. Power failure log book / sheet shall be maintainedFor All Forging Materials, The Specimen Shall Be Taken From The Integral Part of The Forging.Certification requirements shall comply with European Standard EN 10204 (latest edition)In case of conflict between purchase specification, contract documents and QAP, more stringent conditions shall be applicable.



PTS

ReferenceClause No. Manufacturer TPIA

(By EPC Contractor)CLIENT /

CONSULTANT

07 P

4.4 P3 and 4 P

5.4 P1

Each Heat PTS & Mat. Spec. PTS & Mat. Spec. certif. 3.1 P review report review report

2 INPROCESS INSPECTION

2.1 - Each Heat / Length PTS & Mat. Spec. PTS & Mat. Spec. certif. 3.1 P witness point review report

2.2 2 (f) Each length PTS & Mat. Spec. PTS & Mat. Spec. certif. 3.2 P witness point review report

2.3 5.3 1 per lot or heat PTS Cl 5.3, Table 1 & Mat.Spec. PTS Cl 5.3, Table 1 & Mat. Spec. certif. 3.2 P witness point review report

2.4

2.4.1 -

- Base material 1 per lot or heat PTS + E/R <= 0.85 & Mat. Spec.

- Longitudinal weld 1 per lot or heat PTS & Mat. Spec.

2.4.2 - Impact test

2 sets of 3 specimens perlot or heat



2.4.3 - 4.4 & 5.2.3 1 per lot or heat PTS PTS & Mat. Spec.

2.4.4 - 4.4 & 5.2.4 1 per lot or heat PTS Max. 248 HV10 / PTS & Mat. Spec.

2.4.5 - 4.4 & 5.2.5 1 per lot or heat PTS Grain Size : Range 8 to 12

Extent of Check

CONTROL BEFORE UPGRADING

- 3.2 / 3.1 certificates

- non destructive testing procedures- material part list

SCOPE OF INSPECTION

review reportreview report

Nr DocumenttypeApplicable Standard Acceptance criteriaACTIVITY

- LOFC procedures

ISO 148 - Charpy V - Notch

QUALITY ASSURANCE PLANSTATION PIPE

(ASTM A333 Gr. 6 /API 5L GR. X 65/70)

QAP No. : P.013828 D 11013 204

certif. 3.2

5.2.1

ASTM A 370

5.2.2review report

Manufacture of Pipes (Review of MTC,QAP, IRN)

RAW MATERIAL

P

Chemical Analysis & Carbon Equivalent

Inspection & Identificattion (Verification ofHEAT NO. According to Raw Material T.C.)

Hydrostatic test

witness point

- For CS at -20°C Energy is35J/cm²(Avg.), 28J/cm²(Ind.) - For LTCS at -20°C Energy is35J/cm²(Avg.), 28J/cm²(Ind.)and Material Standard’s impact testtemperature requirements or -450C,Whichever is lower.

- Longitudinal weld (Transverse - if notseamless)

- HAZ (Transverse - if not seamless)

Flattening test

Hardness test

Micro test

Mechanical testing(remark : marking transfer by TPIA)

Tension test for fitting ≥ 2" (YS, UTS,YS/UTS, %EL, RA, Bend etc. asapplicable)

- base material(Longitudinal & Transverse)



PTS

ReferenceClause No. Manufacturer TPIA

(By EPC Contractor)CLIENT /

CONSULTANT

Extent of CheckSCOPE OF INSPECTION

Nr DocumenttypeApplicable Standard Acceptance criteriaACTIVITY

QUALITY ASSURANCE PLANSTATION PIPE

(ASTM A333 Gr. 6 /API 5L GR. X 65/70)

QAP No. : P.013828 D 11013 204

3 Non Destructive Testings

3.1 Magnetic Particle Testing All pipes Bevel Ends ASME SEC. VIII DIV. 2 ARTICLE7.5.6.2 P witness point review report

100% of complete surface &welds (if any)

ASME, sectionVIII, division1appendix 12

100% bevels

- defects extending into the bevelprovided the lamination is parallel tothe surface and has a transversedimension exceeding 6.35 mm- all defects not parallel to thesurface extending into the bevel

4 FINAL INSPECTION TEST

4.1 5.1 All accepted pipes PTS & Mat. Spec. PTS & Mat. Spec. certif. 3.2 P witness point review report

4.1 7 All accepted pipes PTS & Mat. Spec. PTS & Mat. Spec. certif. 3.2 P witness point review report

4.2 8 All accepted pipes PTS & Mat. Spec. PTS & Mat. Spec. certif. 3.2 Hold Point witness point witness point

LEGEND:RT: Radiographic test PT: Liquid penetrant test MT: Magnetic particle test HT: Heat treatment TPIA: Third Party Inspection AgencyP: Performed R: Review W: Witness VT: Visual test

Note: 1

2

3

4

5

6

7

89 In case of conflict between purchase specification, contract documents and QAP, more stringent conditions shall be applicable.

witness point review report5.4 All pipes certif. 3.2

TPIA will have Right to Inspect minimum 10% of all manufacturing activities on each day or as specified above.


Contractor in coordination with Sub-vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organise Inspection.



Marking & Tagging

Loaction of Thickness Chechked by TPIA shall be marked with Paint.

Inspector's stamp

The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner/Owner's representative and TPIA.

Certification requirements shall comply with European Standard EN 10204:3.2 (latest edition)

Ultrasonic Testing P3.2

Visual & Dimensional


Revision: 00

VENDORTPIA (BY

EPC)CLIENT /CONSULTANT

1

100% ASTM A 320 L7 / A 194 GR4/GR7 ASTM A 320 L7 / A 194 GR4/GR7 MTC 3.1 R W R

PER HEAT ASTM A 320 L7 / A 194 GR4/GR7 ASTM A 320 L7 / A 194 GR4/GR7 MTC / LAB TEST REPORT 3.1 R R R

PER HEAT ASTM A 320 L7 / A 194 GR4/GR7 ASTM A 320 L7 / A 194 GR4/GR7 INSPECTION REPORT 3.1 R R R

100% ASTM A 320 L7 / A 194 GR4/GR7 ASTM A 320 L7 / A 194 GR4/GR7 INSPECTION REPORT 3.2 P W R

2

100% VENDOR DRG./ ASTM A 320 L7 / A 194GR4/GR7/ ASME B18.2.1&2.2

VENDOR DRG./ ASTM A 320 L7 / A 194GR4/GR7/ ASME B18.2.1&2.2 DIMENSION REPORT 3.1 P R R

100% VENDOR DRG./ ASTM A 320 L7 / A 194GR4/GR7/ ASME B18.2.1&2.2

VENDOR DRG./ ASTM A 320 L7 / A 194GR4/GR7/ ASME B18.2.1&2.2 DIMENSION REPORT 3.1 P R R

2. HEAT TREATMENT 100% ASTM A 370 / A 320 L7 / A194 GR4/GR7/SPECIFICATION.

ASTM A 370 / A 320 L7 / A194GR4/GR7/ SPECIFICATION.

HT GRAPH / INSPECTIONREPORT 3.1 P R R

3.STAMPING OF SAMPLEFOR TESTING 100% ASTM A 370 / A 320 L7 / A194 GR4/GR7/

SPECIFICATION.ASTM A 370 / A 320 L7 / A194

GR4/GR7/ SPECIFICATION. INSPECTION REPORT 3.2 P W R

ONE /HEAT/LOT

ASTM A 370 / A 320 L7 / A194 GR4/GR7/SPECIFICATION.

ASTM A 370 / A 320 L7 / A194GR4/GR7/ SPECIFICATION. INSPECTION REPORT 3.2 P W R

ONE /HEAT/LOT



5 % /HEAT/LOT



ONE /HEAT/LOT

ASTM A 370 / A 320 L7 / A194 GR4/GR7/SPECIFICATION. AVG 27J & IND 20J / SPECIFICATION. INSPECTION REPORT 3.2 P W R

ONE /HEAT/LOT


A 320 L7 / A194 GR4 / GR7 /SPECIFICATION. INSPECTION REPORT 3.1 P R R

5 % /HEAT/LOT A 320 L7 / A194 GR4/GR7/ SPECIFICATION. A 320 L7 / A194 GR4 /GR7 /

SPECIFICATION. INSPECTION REPORT 3.2 P W R

3

100% SPECIFICATION./ ASTM A 320 L7 / A194GR4/GR7

SPECIFICATION./ ASTM A 320 L7 /A194 GR4/GR7 INSPECTION REPORT 3.2 P 100% W R

100% APPRD. DRG./ ASTM A 320 L7 / A194GR4/GR7

APPRD. DRG./ ASTM A 320 L7 / A194GR4/GR7 INSPECTION REPORT 3.2 P 10% W R

4

100% AS PER SPECIFICATION / AS PER APPR.DRG. & QAP

AS PER SPECIFICATION / AS PERAPPR. DRG. & QAP COMPLIANCE CERTIFICATE P R R

100% AS PER SPECIFICATION / AS PER APPR.DRG. & QAP

AS PER SPECIFICATION / AS PERAPPR. DRG. & QAP COMPLIANCE CERTIFICATE H P R

Legend:

NOTE :

QUALITY ASSURANCE PLAN - FASTENERS

QAP No. : P.013828 D 11013 205

Date: 22.04.2019Prepared : MKChecked : RP /SGApproved : NC / SKH

SR. NO COMPONENTS &OPERATIONS TYPES OF CHECK

INSPECTION

RAW MATERIAL

QUANTUMOF CHECK REFERENCE DOCUMENTS ACCEPTANCE NORMS FORMAT OF RECORD

5. IN CASE OF CONFLICT BETWEEN PURCHASE SPECIFICATION, CONTRACT DOCUMENTS AND QAP, MORE STRINGENT CONDITIONS SHALL BE APPLICABLE.

1. HEAT TREATMENT CYCLE (TEMP. / TIMECHART)

4. MECHANICAL TESTING3. HARDNESS TESTING

FINAL DOCUMENTS

4. SAMPLE FROM ANY ONE LOT/HEAT SHALL BE TESTED BY CLIENT UNDER THEIR WITNESS AT ANY NABL ACCREDITED LAB.

FINAL INSPECTION

P-Perform, R-Review, W-Witness, H-Hold, IA - Inspection Agency (Purchaser / Owner's representative).

2. PROOF LOAD TEST

1. MFG. OF BOLT & NUT

INPROCESS INSPECTION.

1. CHEMICAL ANALYSIS

1. RAW MATERIAL

1. VISUAL INSPECTION, MARKING &CORRELATION WITH MANUFACTURE TESTCERTIFICATE)

2. CHEMICAL COMPOSITION

3. MECHANICAL PROPERTIES

1. FINAL DOCUMENTS

1.CUTTING , GRINDING, FORGING,THREADING ETC.

2. PRODUCT DIMENSIONS

4. PMI CHECK

1. VISUAL \ STAMPING \ MARKING \ COLORCODING.

2. DIMENSIONS

2. PMI TEST

1. TPIA SHALL ISSUE 3.2 CERTIFICATE AS PER BS EN 102042. MATERIAL & TYPE SHALL BE AS PER SPECIFICATIONS / DATA SHEET3. START & STOP TEMP. CHART SHALL BE SIGNED BY TPIA, ALSO POWER FAILURE LOG SHALL BE MAINTAINED.

5. PRODUCT CHEMICALCHECK ANALYSIS

1. STAMPING OF TEST SAMPLE

1. TENSILE TESTING (TS,YS,EL%)

1. QAP / PO / MTC / IR / COMPLIANCECERTIFICATES

2. INSPECTION RELEASE NOTE

4. IMPACT TEST AT - 101° C

1.FINAL INSPECTION



MANUF. TPIA/CA

1 Raw Material Inspection

1.1 Insulating Gaskets

1.2 Insulating washer

1.3 Insulating sleeve

1.4 Machine cut washer

2 Final Inspectiom

2.1 Raw Material PHYSICAL , CHEMICAL PTS / Data sheet Test report P W

2.2 Hydrotest and Pneumatic Test Each Batch PTS PTS / Data sheet / ApprovedProcedure Inspection report P W

2.3 Visual & Dimensional check 100% Measurement PTS / Data sheet Inspection report P R

2.4 Marking Each Batch PTS PTS / Data sheet / ApprovedProcedure Inspection report P R

2.5 Packing Each Batch PTS PTS / Data sheet / ApprovedProcedure Inspection report P R

2.6 Documentation PO / PTS PTS / Data sheet Inspection report P W

1

23

4

5

6

7

8

Prepared : MKChecked : RP /SGApproved : NC / SKH

QUALITY ASSURANCE PLANINSULATING GASKET

All reference Codes/ Standards, Documents, P.O. Copies shall be arranged by vendor / supplier for reference of TPIA/CA at the time of InspectionAt the time of deleivery of materail in stores, vendor will submit copy of all related document of inspection along with release note & MTC.

Contractor in coordination with Supplier/Sub vendor shall issue detailed Production and Inspection schedule indicating the dates and the locations to facilitate Owner/Owner's representative and TPIA to organiseInspection.

Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used, in case of conflict between specifications more stringent condition shall be applicable.

Owner / Owner's representative including TPIA will have the right to inspect any activity of manufacturing at any time.

1 sample per heat RPHYSICAL , CHEMICAL PTS / Data sheet Test report H

Notes: -

Owner/Owner representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.

LEGENDS: R - Review, W - Witness, RW - Random Witness, H - Hold, P - Perform, TPIA - Third Party Inspection Agency, CA - Control Authority ( Owner / owner's representative ) , P.O. - Purchase order

The Above Testing and acceptance critera are minimum requirements, however, manufacturer shall ensure that the product shall also comply to the additional requirements as per Particular Technicalspecifications(PTS)The supplier shall submit their own detailed QAP prepared on the basis of above / Technical specification for approval of Owner/Owner's representative.

DESCRIPTION ACCEPTANCE CRITERIAINSPECTION

QUANTUM OF CHECKS. No CHARACTERISTICS DOCUMENTATION

QAP No. :P.013828 D 11013 206

REMARKS



Maf. Client /Consultant

TPIA (By EPCContractor)

Remarks

1 PTS P.011947 M 11097016 Clause No. 4 Each pipe

Hot induction bends shall be fabricated from carbonsteel line pipe (LSAW) of grade API 5L X70 PSL2 asper API 5L &Standard Specification for Longitudinal SeamSubmerged Arc Welded (LSAW) Linepipe, latestrevision of tender documents.

Test Certificate P R R

2 PTS Linepipe Each pipe

As per Owner's specification for line pipes and MTC,Pipe receiveing Report shall be reviewed. Pipes withpositive wall thickness shall be used for fabrication ofbends.

Inspection Report P RW W

3PTS P.011947 M 11097016Clause No. 5.5 --

the longitudinal seam shall be located in the plane ofminimum deformation or neutral axis. Acceptabletolerance on location of the longitudinal weld seam shallbe ± 5°

-- P RW W

4 PTS Linepipe 1 Per heat Inspection Report P R R

5 PTS Linepipe 1 Per heat Inspection Report P RW W

6 PTS Linepipe 1 Per heat Inspection Report P RW W

7

7.1 As per ApprovedManufacturing Procedure Each bend As per Approved Manufacturing Procedure Manufacturer's Report P RW RW

7.2 As per ApprovedManufacturing Procedure Each bend To be frozen after Test bend result . Variation allowed

±2.2mm/minute Manufacturer's Report P RW RW

7.3 As per ApprovedManufacturing Procedure Each bend Heating coil configuration. Induction heating frequency

(tolerance ±20%) Manufacturer's Report P RW RW

Prepared : MKChecked : RP /SG

Tensile tests (YS, UTS, YS/UTS, %EL, RA,Bend etc. as applicable )(remark : marking transfer by TPIA)

Speed

Ref. Standard/Specification

Minnumber of

test

Forming of Bends

Sr. ACTIVITY Procedure/Acceptance criteria

Chemical Composition

Scope of InspectionDocument type

Temperature

Inspection of Bare Pipes

Weld Position

Material

Charpy-test at as per Mat. Spec. (ImpactEnergy & Shear Area)(remark : marking transfer by TPIA)

Hot induction bends shall be fabricated from carbonsteel line pipe (LSAW) of grade API 5L X70 PSL2 asper API 5L &Standard Specification for Longitudinal SeamSubmerged Arc Welded (LSAW) Line pipe, latestrevision of tender documents.

Heating

Approved : NC / SKH

QAP No. : P.013828 D 11013 207

QUALITY ASSURANCE PLAN HOT INDUCTION BEND





Remarks



Minnumber of

testSr. ACTIVITY Procedure/Acceptance criteria


Approved : NC / SKH

QAP No. : P.013828 D 11013 207


7.4 As per ApprovedManufacturing Procedure Each bend

Instant cooling with air & water jet distributeduniformly across the circumference to heated Parameterannular Zone• Coolant flow rate & pressure variation allowed is ±10%.• Coolant temperature variation allowed is ±15° C

Manufacturer's Report P RW RW

7.5 PTS P.011947 M 11097016 Clause No. 5.13 Each bend

± 1% of Nominal Bending Radius (where nominalradius shall be 6D). Manufacturer's Report P RW RW

7.6 As per ApprovedManufacturing Procedure Each bend Temperature against speed record chart Manufacturer's Report P RW RW

8 As per ApprovedManufacturing Procedure -- Bends shall be supplied in as bend condition i.e without

post bend heat treatment -- P RW W

9 As per ApprovedManufacturing Procedure Each bend

Cold forming or sizing without subsequent heattreatment is permitted provided the induced permanentstrain does not exceed 1.5 %.

Log book P RW W

10 PTS P.011947 M 11097016 Clause No. 7.1.g Each bend

By 2 gauging plates of diameter equal to 95% of thenominal internal diameter of the pipe, connected rigidlytogether at a distance equal to 500 mm.

Inspection Report H RW W

11


Circumferentially 25 mm wide band at each endincluding end preparation shall be ends for laminationand inclusion.Acceptance as per line pipe specification.



The complete seam welds of all finished fabricatedfrom welded pipes shall be 100% inspected by X-Raymethod.Acceptance as per line pipe specification.

Inspection Report H R (X-Ray filmreview) R (X-Ray film review)

NON DESTRUCTIVE TEST

Manual Ultrasonic Testing on Bend ends

X-Ray of Weld seam

Sizing (Internal Exterenal)

Pig Gauge Trial

Cooling

Post Bending Heat Treatment/ Stress Relieving(Loading & Unloading shall be witnessed byTPIA, Power failure log shall be maintained)

Pyrometer Setting

Bend Radius





Remarks



Minnumber of



Approved : NC / SKH

QAP No. : P.013828 D 11013 207


11.3 PTS P.011947 M 11097016 Clause No. 7.1 f Each bend

- On the Extrados & Intrados to include the areaencompassed 30° either side of the line passing throughthe plane of the bend.- All Bevel Ends- Acceptance in accordance with WI for MPI / ASMESec. VIII Appendix 6.


12 PTS P.011947 M 11097016 Clause No. 5.9 Each bend No repair by welding is allowed on any part of bends. Repair Report H RW W

13

13.1 PTS P.011947 M 11097016 Clause No. 4.13 Each bend ± 0.50 from the specified angle Inspection Report H RW W

13.2PTS P.011947 M 11097016 Clause No. 5.14 Each bend

Minimum wall thickness shall be equal to t min= 0.95 (tactual - ∆t) where:t actual = Actual wall thickness of pipe used for bending∆t = 0.35 mm for a wall thickness < 10 mm 0.5 mm fora wallthickness ≥ 10 mm

Wall thickness shall be measured along both the insideand outside radii of bend between and including thestart and stop points of the bend arc, at intervalapproximately equal to pipe diameter or 300 mmwhichever is less. Wall thickness shall be measuredultrasonically after bending at the same locations asmeasured before bending. In addition the wall thicknessof the tangents shall also be measured.



At End: 3.0 mm max (Out-of-roundness over a lengthof 100 mm from the end)

At Body: 5.0 mm max


Magnetic Particle Testing on Bend Body &Weld

Out of Roundness

Repair

Bend Angle

VISUAL & DIMENSION INSPECTION

Wall Thickness





Remarks



Minnumber of



Approved : NC / SKH

QAP No. : P.013828 D 11013 207



± 1% of Nominal Bending Radius (where nominalradius shall be 6D). Inspection Report H RW W


Off-Plane of bends shall not exceed (θ/ 90) X 10 mm,where θ is the bend angle in degree or the tolerance limitspecified in MSS-SP-75, whichever is less.


13.6 PTS P.011947 M 11097016 Cl no 5.6

Each bend& Both ends 500 mm or 1pipe OD whichever is more. Inspection Report H RW W

13.7 -- Each bend

Bends shall be supplied with Plane ends.Bevel Angle- 30. (+ 5°, -0°) Root Face - 1.6 mm (± 0.8 mm) Squareness- 1.6 mm Max



Both ends of all bends shall be suitably protected toavoid any damage during transit by means of metallic orhigh impact plastic bevel protectors.

-- P RW M

14

14.1 -- Each Bend ,If any

Bulges dent and flat areas shall not appear within100mm front end of the bend. For the remaining partthese deviations from the original contour of the pipeare permitted provided these deviations do not exceed6.0 mm. The same shall not extend (in any direction)over a distance of more than 25% of nominal diameter ofthe bend.

Inspection Report H RW RW

14.2 -- Each bendExternal and internal reinforcements of longitudinalwelds shall be ground flush for a distance of 100 mmfrom the ends of the Standard bend.

Inspection Report H RW RW

15

15.1 Test Bend On minimum Bend wall thickness at Pressure as perMTC of mother pipe with holding time of 15 Miniutes. Inspection Report H RW W

End Protection

Bend Radius

Bend Irregularities

End Flushing

WORKMANSHIP

Off-Plane (Plane of bends)

Tangent Length

End Preparation

Manufacturing Procedure Qualification Test

Hydrostatic Test





Remarks



Minnumber of



Approved : NC / SKH

QAP No. : P.013828 D 11013 207




- at -20°C, for Base/Weld/HAZ - 35J/cm²(Avg.),28J/cm²(Ind.). - at 0°C, for Base - 100J/cm²(Avg.), 80J/cm²(Ind.),- at 0°C, for Weld/HAZ - 40J/cm²(Avg.), 32J/cm²(Ind.)


Shall not exceed 300 HV 10 Inspection Report H RW WAs per API 5L Inspection Report H RW WGrain size shall be 7 or finer Inspection Report R RW WAs per Line pipe Specification Inspection Report H R R

16 PTS P.011947 M 11097016 Clause No. 9.5

Each bendon theinside

surface atone end

Package shall be marked legibly with suitable markingink to indicate the following:a) Order Numberb) Package Numberc) Manufacturer’s Named) Size (Inches) and Wall thickness (mm)e) Radius of bend (mm)

-- P RW M

17 PTS P.011947 M 11097016 Clause No. 9.3 Each Bend

One coat of anti rust paint shall be applied on outersarface of bends. Type of paint shall be as agreed uponwith the company.

-- P RW M

18 PTS P.011947 M 11097016Clause No. 10 -- All documention shall be done as per specification

P.011947 M 11097 016 Clause 10MTC / Test Reports /

IRN P R R

LEGEND:R : Review RW: Random Witness M: Monitor W:WitnessRT:Radiographic test

TPIA: Third Party Inspection Agency Control Authority : Owner/Engineer or their Authorised Inspection Agency

(*)

Note: 1

Coating

A) Tensile Test

Documentation /Certification

Tests to be specified by the vendor for approval of Owner/Owenr's representative while submission of QAP.

The Above Testing and acceptance criteria are minimum requirements, however, manufacturer shall ensure and also comply to the additional requirements as per Technical specifications.

D) Hardness Test

Marking

15.2 PTS

B) Crossweld Tensile Test

C) Charpy V-Notch- Base Material - 2 sets of 3 specimen per lot- Weld & HAZ - 1 sets of 3 specimen per lot

E) Guided Bend TestF) Metallographic TestG) Chemical Test

Test Bend

As per Line pipe specification.





Remarks



Minnumber of



Approved : NC / SKH

QAP No. : P.013828 D 11013 207


2

3

4

5

6

7

89

10

Manufacturer shall submit detailed production and inspection schedule.

Heat treatment start and stop temperature chart shall be witnessed & signed by TPIA. Power failure log book / sheet shall be maintainedIn case of conflict between purchase specification, contract documents and QAP, more stringent conditions shall be applicable.

Vendor has to submit detailed QAP for Bend Manufacturing Procedure Qualifiacation Production Test and Routine production seperately.

Supplier shall submit Calibration certificates of all Instruments/Equipment to be used for Inspection and Testing with relevant procedures and updated standards for TPIA review/Approval.

TPIA will have to Inspect all manufacturing activities on each day or as specified above.

Certification requirements to comply with EN 10204 - 3.2.to be issues by TPIA appointed by manufacturer.

TPIA along with Owner/Owner's Representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.

The supplier shall submit their own detailed QAP prepared on the basis of above for approval of Owner/Owner's representative and TPIA.


Date: 22.04.2019

MANUFACTURER TPIA CA1

CHEMICALTESTING

100% ASME B 16.20 / ASTM A 240 /Tender Doc.

ASME B 16.20 / ASTM A 240 /Tender Doc.

MTC / LAB TESTREPORT 3.1

P R R

PHYSICAL TESTING PER HEAT ASME B 16.20 / ASTM A 240 /Tender Doc.



P R R

FILLER MATERIAL-GRAPHITE

CHEMICALTESTING

100% AS PER APPLICABLE CODE OFMAT./ ASME B 16.20

AS PER APPLICABLE CODE OFMAT/ ASME B 16.20


P R R

CHEMICALTESTING

100% ASME B 16.20 / ASTM A 240 /Tender Doc.



P R R

PHYSICAL TESTING PER HEAT ASME B 16.20 / ASTM A 240 /Tender Doc.


INSPECTIONREPORT 3.1

P R R

2FINISH DIMENSION FINISH DIMENSION

MEASURMENT OFSPW

100% APPR.VENDOR DRG./ ASTM A 240/ ASME B16.20

APPR.VENDOR DRG./ ASTM A 240/ ASME B16.20

DIMENSIONREPORT 3.1

P R R

COMPRESSION &RECOVERY

TESTING SPW ONE / SIZE /LOT

ASTM A 370 / ASME B16.20 ASTM A 370 / ASME B16.20 INSPECTIONREPORT 3.1

P R R

MARKING VISUAL 100% APPR.VENDOR DRG./ ASTM A 240/ ASME B16.20

APPR.VENDOR DRG./ ASTM A 240/ ASME B16.20


P W R

3VISUAL\ TAGGING \MARKING

100% TENDER SPEC./ ASME B16.20 TENDER SPEC./ ASME B16.20 INSPECTIONREPORT 3.2

P 100% W R

DIMENSIONS 100% APPRD. DRG./ ASTM A 240 /ASME B16.20

APPRD. DRG./ ASTM A 240 / ASMEB16.20


P 100% W R

4QAP / PO / MTC / IR /COMPLIANCECERTIFICATES

100% AS PER TENDER SPEC / AS PERAPPR. DRG. & QAP

AS PER TENDER SPEC / AS PERAPPR. DRG. & QAP

COMPLIANCECERTIFICATE

P R R

INSPECTIONRELEASE NOTE

100% AS PER TENDER SPEC / AS PERAPPR. DRG. & QAP

AS PER TENDER SPEC / AS PERAPPR. DRG. & QAP

COMPLIANCECERTIFICATE

H P R

NOTE :

Prepared : MKChecked : RP /SGApproved : NC / SKH

QUALITY ASSURANCE PLANGASKET

QAP No. : P.013828 D 11013 208

Revision: 00

1. TPIA/VENDOR SHALL JOINTLY ISSUE 3.2 CERTIFICATE AS PER BS EN 10204. ABOVE QAP IS INDICATIVE ONLY. VENDOR SHALL SUBMIT DETAIL QAP FOR APPROVAL.

SPIRAL WOUNDGASKET WINDINGMATERIAL- SS316 /SS316L

OUTER RING-CARBONSTEEL

ACCEPTANCE NORMS

INPROCESS INSPECTION.

RAW MATERIAL

2. MATERIAL & TYPE SHALL BE AS PER TENDER SPECS/DATA SHEET

FORMET OFRECORD

SCOPE O FINSPECTION

RAW MATERIAL

SR. NO COMPONENTS &OPERATIONS

TYPES OF CHECK QUANTAMOF CHECK

REFERENCE DOCUMENTS

FINAL INSPECTION


PIG LAUNCHERY-0101

℄ EL. 101.355

IJ

EXISTING 6" PIPEBOP EL. 101.100

24"-P-10-1002-D1ACL. EL. 101.355

8"-P-10-1003-D1ACL EL. 101.355

1250

PR

OP

OS

ED

EX

IS

TIN

G

EXISTING

12"

PIPE

CL E

L. 101.355

8501100 1100

1350 1000 1000 1000

1000 475

750 700 1000

AG

UG

0101-NG-12"-6C1-N℄ EL. 100.812

700

1100

1100

350

FUTU

RETA

P-OF

F

PG0106

PG0105

PSV0101

XXS0101

PG0104

XXS0102

PG0103

XXS0103

600400550650

12"x12"FLOW TEE.0102-NG-12"-X70-N

℄ EL. 101.355

605 700 450 2000 1426 900 500

350 2250 395 1031 300 650 650 300 500 1100 1100 750

950 525 425

500

650 550 400 600

0104-BD-4"-6C1-N℄ EL. 100.812

TE0103

PG0108

300

525

300 700 1000

300

GOV0101

750

900

500500

500381

300

850

2"-6C1-N℄ EL. 100.812

2"-6C1-N℄ EL. 100.812

CABL

E TR

ENCH

TE0102

PT0102

PT0101

TE0101

2" P

IPE

PURG

E CO

NN.

2" P

IPE

PURG

E CO

NN.

2" PIPEPURGE CONN.

550

650

600

600

350

1300 452

A

11

750

6501000

3003

50 800

850300300300

400 300

200

900

50002200

2561*

0104-NG-4"-6C1-N℄ EL. 101.355

0105-NG-4"-6C1-N℄ EL. 101.355

CPCC

2

2

A

5000 5000 5000

0104-NG-4"-6C1-N℄ EL. 100.812

2"-6C1-N℄ EL. 100.812

750

2500

800

1665

*

24"-P-10-1002-D1ACL. EL. 101.355

CROSSOVER

FILTRATION UNIT & PRESSURE REDUCTION UNIT

METERING SKID

SC-1001

24"24" 12"6"

2050

0103-NG-12"-X70-N℄ EL. 98.538

3234

PS- 04 PS- 06

PS- 01

PS- 05

PS- 02

PS- 03

PS- 07PS- 08

PS- 10 PS- 09 750

PS

-3

0

PS

-1

2

PS

-1

1

PS- 17

PS

-1

3

PS- 14 PS- 15 PS- 16

PS- 18

PS- 19 PS- 20 PS- 21 PS- 22 PS- 23 PS- 24

PS- 31 PS- 32 PS- 33 PS- 34

PS- 35

PS- 39

PS- 36

PS- 37

PS- 38

PS

-4

0

2888 12833

EXISTING CONTROL ROOMBUILDING

CL. OF ROAD

PG0207

500

644

24"-

P-10-100

1-D1

ACL

. EL. 101.355

100.150TOP

100.150TOP

EXISTING PROCESS AREA

3000

27000

1850

3150

PIG HANDLINGAREA

0103-BD-2"-6C1-NPROPOSED PROCESS AREA

PROPOSED PROCESS AREA

0107

-NG-

12"-

6C1-N

℄ EL

. 101.355

12"x

12"

EQ. T

EE.

2"-6

C1-N

℄ EL

. 101.355

Th

is d

ocu

me

nt is th

e p

ro

pe

rty o

f T

RA

CT

EB

EL

E

NG

IN

EE

RIN

G IN

DIA

, a

ny d

up

lica

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n o

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itio

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th

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p

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ith

ou

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pp

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va

l.

Project No. Discipline Code System Code Serial No.

SheetSize Scale

SUBJECT

PROJECT

CUSTOMER

TRACTEBEL Engineering pvt. ltd.

Rev.

GAIL (India) LIMITED

GAIL

HMEL CONNECTIVITY PIPELINE PROJECT

BHATINDA

PIPING GENERAL ARRANGEMENT

DISPATCH STATION

AT NFL BHATINDA

A1 1:75 1 of 20

P.013828 D 21095 201

1. ALL DIMENSIONS ARE IN MILLIMETERS, AND LEVELS ARE IN METERS UNLESS OTHERWISE SPECIFIED.

2. FOLLOW WRITTEN DIMENSIONS ONLY. DO NOT SCALE, ASK IF ANY DOUBT.

3. FLAPPER SHALL BE PROVIDED BY THE CONTRACTOR FOR EQUIPMENT VENTS. VENT SHALL BE LOCATED ATSAFE HEIGHT (3 METER ABOVE THE HIGHEST WORKING PLATFORM).

4. ALL CROSS OVER AND PLATFORMS FOR VALVES/VENT OPERATION AND MAINTENANCE SHALL BE PROVIDEDAT SUITABLE LOCATIONS AS PER SITE CONDITIONS AND INSTRUCTIONS OF ENGINEER IN-CHARGE.

5. ALL PIPING MATERIAL SHALL BE AS PER PMS AND RELEVANT DATA SHEETS /SPECIFICATIONS.

6. PAINTING / COATING OF ABOVE GROUND / UNDERGROUND PIPING SHALL BE DONE AS PER PROJECTSPECIFICATION.

7. PUP PIECE LENGTH FOR BW VALVES SHALL BE AS PER PMS AND VALVE DATA SHEETS.

8. TYPICAL INSTRUMENTATION CONNECTION DETAILS SHALL BE AS PER TE STANDARD DRAWING ATTACHED INTENDER.

9. TOP OF PROPOSED PROCESS AREA (TOP) EL.100.150. CORRESPONDS TO TOP OF NEAREST INTERNAL ROADPLUS 150mm.

10. CORROSION RESISTANT PIPE COATING SHALL BE EXTENDED TO 500 mm (MIN.) ABOVE GROUND FROM ABOVEGROUND/BURIED TRANSITION POINT.

11. TAP-OFF FOR PROPOSED PIPELINE SHALL BE TAKEN FROM EXISTING 12" TAP-OFF PROVIDE BY GAIL.

12. DE-PRESSURISATION LINE TO BE TAKEN AT A SAFE DISTANCE FROM THE PIPELINE FACILITY AS PER PNGRBGUIDELINES AND VENT AT A SAFE HEIGHT (MIN. 3M ABOVE THE HIGHEST WORKING PLATFORM WITHIN ARADIUS OF 15 M) WITH QOEC.

13. CP & CC SHALL BE AT LOWEST POINT & AT 6 O'CLOCK POSITION.

14. COPPER JUMPERS SHALL BE PROVIDED AT FLANGES AND OTHER POINTS OF ELECTRICAL DISCONTINUITY.

LEGEND BALL VALVE AG ABOVE GROUND PIPE

GLOBE VALVE UG UNDER GROUND PIPE

CHECK VALVE BOP BOTTOM OF PIPE

PLUG VALVE ℄ CENTER LINE OF PIPE

TOP OF PROCESS AREA FGL FINISHED GROUND LEVEL

PIPE SUPPORT FPL FINISHED PAVED LEVEL

SPECTABLE BLIND TOP TOP OF PROCESS AREA

PROCESS AREA TOG TOP OF GRATING

ABOVE GROUND PIPE EXISTING PIPE & FACILITIES

UNDER GROUND PIPE PACKAGE UNIT BOUNDARY

PS

NOTES

Rev. D M Y Modifications Drawn Checked Approved Validated

0 18-04-2019 ISSUED FOR TENDER. JV MS NC SKH

REFERENCE DRAWINGS.NO. DRAWING TITLE DRAWING NO.

1 PIPING & INSTRUMENTATION DIAGRAM, DISPATCH STATION AT NFL BHATINDA P.013828-D-21095-101

N

MATC

H LINE

A-A

REF

ER (SH

EET

02 O

F 02

)

AutoCAD SHX Text

JIB CRANE

AutoCAD SHX Text

2

AutoCAD SHX Text

1

AutoCAD SHX Text

3

AutoCAD SHX Text

4

AutoCAD SHX Text

5

AutoCAD SHX Text

6

AutoCAD SHX Text

7

AutoCAD SHX Text

8

AutoCAD SHX Text

A

AutoCAD SHX Text

B

AutoCAD SHX Text

C

AutoCAD SHX Text

D

AutoCAD SHX Text

E

700659

0102-BD-2"-6C1-NCL. EL. 100.500

1" PIPE (DRAIN)CL EL. 100.300

0105-BD-2"-6C1-NCL EL. 100.450

2"

450 500500400617450

533

450

450

623

500

3813002003001828

400700

200500

300

371

450

450

400

450

1155

450

500

371

975

PIG LAUNCHER

Y-0101

℄ EL. 101.355

2"

2"

2" 2"

2"

PS- 02PS- 01 PS- 31 PS- 32 PS- 33 PS- 34

TOP. EL. 100.150FGL. EL. 100.000

PS- 30

400

425

480

425

330

FLOW TEE12"x12"

1100 1100 550 1000 1000 1000

PS- 04

PS- 03 PS- 05 PS- 06

484

671

2"

2" IJ805

2234 2693

805

0103-NG-12"-X70-N℄ EL. 98.538

VIEW A-A

500

BAREPIPE

3LPECOATING

R=6D(1944)BEND 45°

AGUG

0102-NG-12"-X70-N℄ EL. 101.355

(NOTE-10)

500

500

500

500

1373

R=6D(1944)BEND 45°

500

PG0106

P50103

PSV0101

XXS0101

PG0104

XXS0102

PG0103

XXS0103

950

TOP. EL. 100.150FGL. EL. 100.000

2" PIPE (UC)CL EL. 100.600

6002"

PLTF EL. 102.200

EL. 103.000

PLTF EL. 102.200

0104-BD-4"-1C1-N℄EL. 100.812

FGL EL. 100.000

DETAIL - A

X X

VIEW - X

4" PIPE

50

10∅ TELLTALE HOLE

500

1" DRAIN PIPE℄ EL. 100.500

QOEC

120°

120°

120°

PIPING

INST

.

DETAIL OF TT / TE(TYP.)

2"

2" WNRFFLANGE

500

PIPE

DETAIL OF PT / PI(TYP.)

2"

2"

671

550

PIPE

PIPING

INST

.

TEXXXXTT

XXXX

PTXXXX

PIXXXX

550

671

PURGE CONNECTION(TYP.)

PIPE

2"

2"

535

DETAIL OF PG

2"

4" PIPERED. TEE4"x2"

2" 2"

500

500

510

500

PG208

PIPING

INST

.TO

SV STATION

2950 3400

1600

4500

1" PIPE(DRAIN)

500

0104

-BD-

4"-6

C1-N

℄ EL

. 100

.812

DETAIL-A

QOEC(SEE NOTE-12)

24"-

P-10-100

1-D1

ACL

. EL. 101.355

PS- 25

PS- 26

PS- 28

912 500

0103-NG-12"-X70-N℄ EL. 98.538

R1944

500

1299

150

020

56

R1944

5000103-NG-12"-X70-N℄ EL. 98.538

CL. E

L. 101.355

EXISTING

PRO

CESS

ARE

A

CL. OF ROAD

CL. O

F RO

AD

0101-NG-12"-6C1-N℄ EL. 101.355

0101-NG-12"-6C1-N℄ EL. 100.812

EXISTING 6" PIPE℄ EL. 101.100

EQ. TEE12"x12"

TOP. EL. 100.150

FGL. EL. 100.000

1300

452

290

VIEW 1-1

284

VIEW 2-2

CP CC

850350300457543

0102-NG-12"-X70-N℄ EL. 101.355

0101-NG-12"-6C1-N℄ EL. 100.812

TOP. EL. 100.150

FGL. EL. 100.000

FLOW TEE12"x12"

Th

is d

ocu

me

nt is th

e p

ro

pe

rty o

f T

RA

CT

EB

EL

E

NG

IN

EE

RIN

G IN

DIA

, a

ny d

up

lica

tio

n o

r tra

nsm

itio

n to

th

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p

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ith

ou

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l.


SheetSize Scale

SUBJECT

PROJECT

CUSTOMER


Rev.


GAIL


BHATINDA


DISPATCH STATION

AT NFL BHATINDA

A1 NTS 2 of 20

P.013828 D 21095 201











11. TAP-OFF FOR PROPOSED PIPELINE SHALL BE TAKEN FROM EXISTING 12" TAP-OFF PROVIDE BY GAIL.













UNDER GROUND PIPE

PS

NOTES


1 PIPING & INSTRUMENTATION DIAGRAM, DISPATCH STATION AT NFL BHATINDA P.013828-D-21095-101



MATC

H LINE

A-A

REF

ER (SH

EET

01 O

F 02

)

AutoCAD SHX Text

2

AutoCAD SHX Text

1

AutoCAD SHX Text

3

AutoCAD SHX Text

4

AutoCAD SHX Text

5

AutoCAD SHX Text

6

AutoCAD SHX Text

7

AutoCAD SHX Text

8

AutoCAD SHX Text

A

AutoCAD SHX Text

B

AutoCAD SHX Text

C

AutoCAD SHX Text

D

AutoCAD SHX Text

E

1000

850

850

1450 14501500 1000

300

1000 19600

600 850 500 650

TT0201

3300

27000

FROMDESPATCHSTATION

TORECEIVINGSTATION

0201-NG-12"-6C1-N℄ EL. 98.860

NC NC

PT0201

TT0202

PT0202

4000 4000 4000

NC

UG AG

0201-B

D-4"

-6C1-N

℄ EL

. 99.39

3

0202

-BD-

4"-6

C1-N

℄ EL

. 99.39

3

1000

PS- 03 PS- 06

PS-05

600

PS-10

PS-11

PS-12

300

A

A

7000

FFL. 100.450

PROCESS AREA

GOV0201

850PS

-04

500500

IG

350 700 300 800

NC

PG0203

TT0203

0203-BD-4"-6C1-N℄ EL. 100.950

PS-07

PS-08

PS-09

NC

14003200

QOEC(SEE NOTE-10)

1" P

IPE

(DRA

IN)

500

PS-13

120°

PS- 01 PS- 02

2700

1350

1000

850

522

400

450

PS-16

628

1000

PURGECONNECTION

750

IJ

900

2"-6

C1-N

℄ EL

. 101.450

PS-14

PS-15

0202

-NG-

12"-

6C1-N

℄ EL

. 101.450

1000

FLOW TEE12"x12"

1000

FUTURETAP-OFF

2700

703

FGL EL. 100.000

TOP EL. 100.450

PS-03

1000 300 300 850 850

2"

RED TEE4"x2"(TYP.)

2"

NC

0201-NG-8"-6C1-N℄ EL. 98.690

0201-BD-4"-6C1-N℄ EL. 99.393

TT0201

PT0201

0203-BD-4"-6C1-N℄ EL. 100.950

VIEW A-A

AGUG

607

450

500

607

RF PAD

PLTF EL. 102.650

EL. 103.450

PLTF EL. 102.650

0203-BD-4"-6C1-N℄EL. 100.950

TOP EL. 100.450

DETAIL - A

X X

VIEW - X

4" PIPE

50

10∅ TELLTALE HOLE

500


QOEC

120°

120°

120°


TOP. EL. 100.450

4" PIPE

AGUG


TOP. EL. 100.450

4" PIPE

2"

2"

671

550

RED. TEE4"x2"

RED. TEE4"x2"

TTXXXXTE

XXXX

PTXXXX

PIXXXX

2"

2" WNRFFLANGE

550

PIPING

INST

.

PIPING

INST

.

AGUG

550

671

PURGE CONN.

PIPE

2"

2"

535

DETAIL OF PG

2"

PG0203


2" 2"

500

500

510

500

PIPING

INST

.




1 PIPING & INSTRUMENTATION DIAGRAM, SV STATION P.013828-D-21095-102

2 PLOT PLAN - SV STATION P.013828-D-21028-002

Th

is d

ocu

me

nt is th

e p

ro

pe

rty o

f T

RA

CT

EB

EL

E

NG

IN

EE

RIN

G IN

DIA

, a

ny d

up

lica

tio

n o

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nsm

itio

n to

th

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p

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ou

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l.


SheetSize Scale

SUBJECT

PROJECT

CUSTOMER


Rev.


GAIL


BHATINDA


SV STATION

A1 1:50 1 of 10

P.013828 D 21095 202

NOTES







7. TOP OF PROPOSED PROCESS AREA (TOP) EL. 100.450. CORRESPONDS TO TOP OF NEAREST INTERNAL ROADPLUS 300mm.

8. DISTANCE BETWEEN FLOW TEE & UNDER GROUND TO ABOVE GROUND TRANSITION AI 40M (APPROX.) ANDVALVE LOCATION IS TENTATIVE. THE SAME SHALL BE FINALIZED LATER BASED ON PLOT FINALATION.











ABOVE GROUND PIPE

UNDER GROUND PIPE

GOLDEN JOINT

PS

AutoCAD SHX Text

2

AutoCAD SHX Text

1

AutoCAD SHX Text

3

AutoCAD SHX Text

4

AutoCAD SHX Text

5

AutoCAD SHX Text

6

AutoCAD SHX Text

7

AutoCAD SHX Text

8

AutoCAD SHX Text

A

AutoCAD SHX Text

B

AutoCAD SHX Text

C

AutoCAD SHX Text

D

AutoCAD SHX Text

E

FILT

ER S

KID

METE

RING

SKID

PRS

SKID

4500

4000

4200

0

UG

AG

500

2245

0304

-NG-

4"-6

C1-N

℄ EL

. 100

.750

500

650

425

525

950

300

650

650

300

750

1350

4750

431

950 550 400 522628 850

1000

1350

550

400

628

522

0301-N

G-12"-

X70-

N℄

EL. 1

01.650

IJ

700

600

428

650

522

500

850

1150

1000

3234

2889

1000

650

475

1250

500225

225175

4775

700

650

1200

275

650

2730

600

3500

1500

1000

4500

4350

219

831

1050

380

CPCC

300

300

TE0302

PT0302PG

0302

750

TE0301

PT0301PG0301

GOV0301

2" PIPEPURGE CONN.

FUTURETAP-OFF

EQ. TEE12"x12"

0307

-NG-

12"-

6C1-N

℄ EL

. 101.650

2"-6C1-N℄ EL. 101.650

2"-6

C1-N

℄ EL

. 101.650

0303

-BD-

4"-6

C1-N

℄ EL

. 101.650TE

0303

PG0308

0303

-BD-

4"-6

C1-N

℄ EL

. 100

.500

PG0303

XXS0302

1000

12"x

12"

FLOW

TEE

.

1150 750

300

PSV030170

046

4

0306

-NG-

H"-6

C1-N

0301-B

D-H"

-6C1-N

PIG

RECE

IVER

Y-03

01℄

EL. 1

01.650

PIG

HAND

LING

AREA

0304

-BD-

2"-6

C1-N

℄ EL

. 100

.750

0302

-NG-

2"-6

C1-N

450

500

2000

500

1426

400

250

1100

PG0306

PG0305

XXS0303

0304

-NG-

4"-6

C1-N

℄EL

. 101.650

500

500

1150

2"-6

C1-N

℄ EL

. 101.650

1100

1100

3520

4VE

NDOR

PIPING

PIPING

VE

NDOR

0303-NG-12"-6C1-N℄ EL. 101.650

132010501050800

2" P

IPE

PURG

E CO

NN.

550 400 628 522

750

2"-6C1-N℄ EL. 101.650

EX

IS

TIN

G

PR

OP

OS

ED

20000

8000

4980

1376

6

PS

-0

4

PS

-0

6

PS

-0

1

PS

-0

5

PS

-0

2

PS

-0

3

PS

-0

7P

S-

08

PS- 09

PS- 10 PS- 11

PS- 12PS- 13

PS

-1

5P

S-

14

PS

-1

6P

S-

17

PS

-1

8

PG0307

PS

-2

0P

S-

19

PS

-2

3

PS

-2

1

PS

-2

2

PS

-2

4P

S-

25

PS

-2

6

PS- 32

PS- 35

PS- 36

PS- 34

PS- 33

UTILITY

CONN

.℄

EL. 1

00.650

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PS

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9

PS

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8

PS

-4

0

PS

-4

1

PS- 42

PS- 43

0301-N

G-12"-

X70-

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8

8000

1000

01600

0

4000

100.450TOP

PROCESS AREA

PROCESS AREA

1600A

A

1120

3000

800

20002000

1500

8657

2016

PS

-0

8A

780

FR

OM

SV

S

TA

TIO

N

DETAIL-A 1" P

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(DRA

IN)QOEC

(SEE NOTE-12)

500

PS- 31

2270

5000

5000

1600

34003350

PS

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PS

-28

PS

-29

PS- 30

0303

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SUBJECT

PROJECT

CUSTOMER


Rev.


GAIL


BHATINDA


RECEIVING STATION

AT HMEL BHATINDA

A1 1:75 1 of 20

P.013828 D 21095 203












12. DE-PRESSURISATION LINE TO BE TAKEN AT A SAFE DISTANCE FROM THE PIPELINE FACILITY AS PER PNGRBGUIDELINES AND VENT AT A SAFE HEIGHT (MIN. 3M ABOVE THE HIGHEST WORKING PLATFORM WITHIN ARADIUS OF 15 M) WITH QOEC. .











UNDER GROUND PIPE PACKAGE UNIT BOUNDARY

PS

NOTES


1 PIPING & INSTRUMENTATION DIAGRAM, RECEIVING STATION AT HMEL BHATINDA P.013828-D-21095-103

2 PLOT PLAN - RECEIVING STATION AT HMEL BHATINDA P.013828-D-21028-003



MATCH LINE A-A

MATCH LINE A-A

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1

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3

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4

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5

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6

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7

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8

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A

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B

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C

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D

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700659

0302-BD-2"-6C1-NCL. EL. 100.800

1" PIPE (DRAIN)CL EL. 100.600

0304-BD-2"-6C1-NCL EL. 100.750

2"

450 500500400617450

533

450

450

623

500

3813002003001828

400700

200500

300

371

450

450

400

450

1155

450

500

371

975

PIG RECEIVER

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℄ EL. 101.650

2"

2"

2" 2"

2"

PS- 02PS- 01 PS- 33 PS- 34 PS- 35 PS- 36

TOP. EL. 100.450

FGL. EL. 100.000PS- 32

400

425

480

425

FLOW TEE12"x12"

1100 1100 550 1000 1000 1000

PS- 04

PS- 03 PS- 05 PS- 06

484

671

2"

2" IJ805

2234

VIEW A-A

500

BAREPIPE

3LPECOATINGAGUG

0301-NG-12"-X70-N℄ EL. 101.650

(NOTE-10)

500

500

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500

PG0306

P50305

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PG0304

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PG0303

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TOP. EL. 100.450

FGL. EL. 100.000

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500

500

1650

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575

PLTF EL. 102.200

EL. 103.000

PLTF EL. 102.2000403-BD-4"-6C1-N

℄EL. 100.500

FGL EL. 100.000

DETAIL - A

X X

VIEW - X

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50

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500


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120°

120°

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INST

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2"

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SUBJECT

PROJECT

CUSTOMER


Rev.


GAIL


BHATINDA


RECEIVING STATION

AT HMEL BHATINDA

A1 NTS 2 of 20

P.013828 D 21095 203












12. DE-PRESSURISATION LINE TO BE TAKEN AT A SAFE DISTANCE FROM THE PIPELINE FACILITY AS PER PNGRBGUIDELINES AND VENT AT A SAFE HEIGHT (MIN. 3M ABOVE THE HIGHEST WORKING PLATFORM WITHIN ARADIUS OF 15 M) WITH QOEC. .











UNDER GROUND PIPE

PS

NOTES




1 PIPING & INSTRUMENTATION DIAGRAM, RECEIVING STATION AT HMEL BHATINDA P.013828-D-21095-103

2 PLOT PLAN - RECEIVING STATION AT HMEL BHATINDA P.013828-D-21028-003

AutoCAD SHX Text

2

AutoCAD SHX Text

1

AutoCAD SHX Text

3

AutoCAD SHX Text

4

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5

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6

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7

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8

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A

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B

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C

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D

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E

At the helm of the Energy Transition, Tractebel provides a full range of engineering and advisory servicesthroughout the life cycle of its clients’ projects, including design and project management. As one of the world’sleading engineering and advisory companies and with more than 150 years of experience, it's our mission toactively shape the world of tomorrow. With about 5,000 experts and presence in more than 70 countries, we areable to offer our customers multidisciplinary solutions in energy, water and urban.

TRACTEBEL ENGINEERING PVT. LTD.Intec House 37Institutional Area, Sector 44122 002 - Gurgaon - INDIAtractebel-engie.com

Syed Kaiumul HUSSAINtel. +91 124 669 [email protected]

LAYING AND ASSOCIATED WORKS FOR HMEL CONNECTIVITY...

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