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VOLUME II

PIPELINE ENGINEERING

SPUR LINES OF CHAINSA JHAJJAR PIPE LINE

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

REV.

DATE

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

S. NO. 1 2 3 4 5 6 7

TITLE

REV.

SPEC.

No. of Pages 19 68 52 01 02 06 15

JOB SPECIFICATION Engineering Design Basis Piping Material Specification Welding Specification for Mainline for Transportation of Gas Welding Specification Chart Welding Specification Chart Specification for Geo Textile bags for Anti-Buoyancy Technical Specification for PreCommissioning and Commissioning 0 0 0 0 0 0 0 0001-01-04-03-001 0001-01-05-02-001 0001-01-04-02-001 0001-01-04-02-001-WSC1 0001-01-04-02-001-WSC2 0001-01-04-02-002 0001-01-04-02-003

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

S-04-02-001 S-04-02-002 S-04-02-003 S-04-02-004 S-04-02-005 S-04-02-006 S-04-02-007 S-04-02-008 S-04-02-012 S-04-02-013

36 43 06 34 34 31 17 14 14 07

Page 1 of 7

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

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

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

S-04-02-014 S-04-02-015 S-04-02-016 S-04-02-017 S-04-02-018 S-04-02-019 S-04-02-020 S-04-02-021 S-04-02-022 S-04-02-023 S-04-02-024 S-04-02-025 S-04-02-026 S-04-02-027 S-04-02-028 S-04-02-029 S-04-02-030 S-04-02-031 S-04-02-032 S-04-02-033 S-04-02-034 S-04-02-035

07 10 12 17 6 9 08 15 15 06 08 15 11 15 43 22 05 09 11 17 32 10

Page 2 of 7

33 34

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

0 0

S-04-02-036 S-04-02-037

09 06

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

0 0 0 0 0 0 0 0 0 0 0 0

S-05-02-001 S-05-02-002 S-05-02-003 S-05-02-004 S-05-02-005 S-05-02-006 S-05-06-001 S-05-02-011 S-05-02-012 S-05-02-013 S-05-02-014 S-14-02-001

09 17 07 05 03 03 04 16 16 10 49 07

0 0 0 0 0 0 0 0

S-04-01-001 S-04-01-002 S-04-01-003 S-04-01-004 S-04-01-005 S-04-01-006 S-04-01-007 S-04-01-008

02 01 01 01 02 01 01 01 Page 3 of 7

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

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

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

S-04-01-009 S-04-01-010 S-04-01-011 S-04-01-012 S-04-01-013 S-04-01-014 S-04-01-015 S-04-01-016 S-04-01-017 S-04-01-018 S-04-01-019 S-04-01-020 S-04-01-021 S-04-01-022 S-04-01-023 S-04-01-024 S-04-01-026 S-04-01-027 S-04-01-028 S-04-01-029 S-04-01-030 S-04-01-031

02 02 02 02 01 03 02 03 03 03 02 02 02 03 03 03 02 02 03 02 01 01

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

0 0 0 0 0 0

S-05-01-001 S-05-01-002 S-05-01-003 S-05-01-004 S-05-01-005 S-05-01-006

01 01 01 01 02 01 Page 4 of 7

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

PA, PC etc Handle Projections for Spacers and Blinds T-Strainer Type-1 2"-4" (150# RF, 300# RF and RTJ, 600# RF and RTJ) T-Strainer Type-1 6"-24" (150# RF, 300# RF and RTJ, 600# RF and RTJ) Orientation of Orifice Traps Stub-in Standard Welding of pipe with different thickness Fillet weld details Welding details for branch connections Method of cutting and dimensions of field manufactured concentric reducers Tolerances for fabrication Pipe shoe for hot insulated C.S. pipe, size 2" thru 8", Type-S1 (for temp. up to 343C) Pipe shoe for hot insulated C.S. pipe, size 10" thru 30", Type-S2. (for temp. up to 343C) Pipe saddle for bare pipe size 14 thru 48 type- S6A Pipe shoe for slope line pipe size 2" thru 6" type-S9A/9B/9C Low support sliding for bare and insulated pipe size 2" thru 36" type-L1 & L1A Low support fixed for bare & insulated pipe size 2" thru 36" type-L3 & L3A. Low support sliding for bare pipe size 3/4" thru 36" type-L5 & L5A. Low support sliding for bare and insulated pipe size 2 thru 36 Type-L6 Low support Fixed/Restrained for bare and insulated pipe size 2" thru 36", type-L7 & L7A

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

S-05-01-007 S-05-01-008 S-05-01-009 S-05-01-010 S-05-01-011 S-05-01-012 S-05-01-013 S-05-01-014 S-05-01-015 S-05-01-016 S-05-01-017 S-05-01-018 S-05-01-019 S-05-01-020 S-05-01-021 S-05-01-022 S-05-01-023 S-05-01-024 S-05-01-025

01 01 01 01 02 01 01 01 01 01 02 02 02 02 02 01 01 02 03

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26 27 28 29 30 31

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

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

0 0 0 0 0 0

S-05-01-026 S-05-01-027 S-05-01-028 S-05-01-029 S-05-01-030 S-05-01-031

01 01 02 01 02 01

0 0 0 0 0 0 0 0 0 0 0 0 0

S-05-01-032 S-05-01-033 S-05-01-034 S-05-01-035 S-05-01-036 S-05-01-037 S-05-01-038 S-05-01-039 S-05-01-040 S-05-01-041 S-05-01-042 S-05-01-043 S-05-01-044

02 01 01 02 02 01 01 02 02 02 02 01 01

Page 6 of 7

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

0001-00-10-01-6002 0001-00-10-01-6003 0001-00-10-01-6004 0001-00-10-01-6005 0001-00-10-01-6006 0001-00-10-01-6007 0001-00-10-01-6008 0001-00-10-01-6009 0001-00-10-01-6010 0001-00-10-01-6011 0001-00-10-01-6012 0001-00-10-01-6013 0001-00-10-01-6014 0001-00-10-01-6015

01 01 01 01 01 01 01 01 01 01 01 01 01 02

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0001-01-04-04-BV-001 0001-01-04-04-BV-002 0001-01-04-04-BV-003 0001-01-04-04-PL/PR-001 0001-01-04-04-PSG-001 0001-01-04-04-IJ-001 0001-01-04-04-FLT-001 0001-01-04-04-FLT-002 0001-01-04-04-FLT-003 0001-01-04-04-QOEC-001 0001-01-04-04-GVA-001 0001-01-04-04-PV-001 0001-01-04-04-PV-002 0001-01-05-04-GV-001

01 01 01 01 01 01 01 01 01 01 04 01 01 03

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ENGINEERING DESIGN BASIS (PIPELINE ENGINEERIG)


SPUR LINES OF CHAINSA JHAJJAR PIPELINE

ENGINEERING DESIGN BASIS GAIL (INDIA) LTD NEW DELHI PIPELINE ENGINEERING

SPECIFICATION 0001-01-04-03-001

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TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 ANNEXURE-A

INTRODUCTION SCOPE DESIGN CODES AND STANDARDS DESCRIPTION OF FACILITIES PIPELINE ROUTE DESIGN DATA PIPELINE AND ASSOCIATED FACILITIES DESIGN OTHER TECHNICAL REQUIREMENTS LIST OF CODES AND STANDARDS

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

ENGINEERING DESIGN BASIS GAIL (INDIA) LTD NEW DELHI PIPELINE ENGINEERING

SPECIFICATION 0001-01-04-03-001

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1.0

INTRODUCTION M/s GAIL (India) Ltd., proposes to lay following Natural Gas spur Pipelines (from Chainsa- Jhajjar pipeline):Sl. Pipeline Tap-off Point Size(Inch) X Length (Km)

Sultanpur Haryana) to Neemrana (Rajasthan) Spur Line to Bhiwadi

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

18 X 85.28

Tap-off point at Chainage 12 X 9 31.6 Km in Sultanpur Neemrana Line Tap-off point at Chainage 61.14 Km in Chainsa-Jhajjar line 10 X 5.4

Hayatpur to Manesar Hayatpur to Gurgaon

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

These pipelines are to cater the natural gas requirement of consumers at Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar and Khandsa/Gurgaon. The Sultanpur-Neemrana pipeline is proposed to pass through Dharuhera and Khushikhera. The above proposed pipeline shall have laying length as given above and 4 nos. of Sectionalising Valve (SV) stations. The pipeline shall be designed to handle Natural Gas & RLNG. 2.0 SCOPE This document establishes minimum design parameters and basis for design and detailed engineering of the Pipeline and Associated facilities covered under this project as defined briefly herein below. 3.0 DESIGN CODES AND STANDARDS Pipelines and terminal facilities envisaged shall be designed and engineered
ENGINEERING DESIGN BASIS GAIL (INDIA) LTD NEW DELHI PIPELINE ENGINEERING SPECIFICATION 0001-01-04-03-001 REV-0 Page 3 of 19

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primarily in accordance with the provisions of the latest edition of Code ASME B 31.8: Gas Transmission and Distribution Piping Systems and OISD 141: Design and Construction Requirements for Cross Country Hydrocarbon Pipelines. In addition, requirements, as applicable to gas service of following codes/standards shall be complied with: OISD Std. 138 ASME B 31.3 API Std. 1102 API Std. 1104 ISO 13623 Inspection of Cross Country Pipelines-Onshore Chemical Plant & Petroleum Refinery Piping Steel Pipeline Crossing Railways & Highways Standard for Welding Pipelines and Related Facilities Petroleum & natural gas industries Pipeline transportation systems

In addition to above, codes and standards listed in Annexure-A of this document shall also be referred. In case of conflict between the requirements of ASME B31.8/OISD 141 and other codes/Standards referred above, requirement of ASME B 31.8/OISD 141 shall govern. In case of conflict between requirements of B31.8/OISD 141 and this document, requirements of this document shall govern. 4.0 DESCRIPTION OF FACILITIES Details of facilities shall be as per P&IDs, process design basis, data sheets, line schedule etc covered in the process package. The pipeline facilities envisaged as a part of Spur Line of Chainsa-Jhajjar Pipeline are described briefly herein below. 4.1 SULTANPUR NEEMRANA LINE Facilities at Despatch cum Receipt Station at Sultanpur & Neemrana terminals shall consist of Pig launcher cum receiver complete with associated piping including hook-up with existing Chainsa-Jhajjar Pipeline at Chainage 70.50 Km in Sultanpur. Additionally Neemrana terminal shall have filtering, metering and let down skid (CGS). 4.1.2 SV & TOP at SV-1 (Ch. 16.02 Km), SV-3 (Ch. 62.2) Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Sectionalizing Valve in Main line. 4.1.3 TOP & CGS at Dharuhera, Bhiwadi Tap-off with flow tee and valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline. Filtering, metering and let down skid with associated piping and Instruments.
ENGINEERING DESIGN BASIS GAIL (INDIA) LTD NEW DELHI PIPELINE ENGINEERING SPECIFICATION 0001-01-04-03-001 REV-0 Page 4 of 19

4.1.1 Despatch cum Receipt Station at Sultanpur and Neemrana

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

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

4.3.1 PRS at Hayatpur Extending the existing Tap-off off with PRS/ valve. Provision for Insulating Joint at the buried/above ground transition in the above ground section of pipeline 4.3.2 SV-1 Gurgaon Line (Ch. 6.4 Km) Sectionalizing Valve (underground) at Chainage 6.4 Km. 4.3.2 Gurgaon Terminal Station Provision for Insulating Joint at the buried/ above ground transition in the above ground section of pipeline. Tap-off with Valve and Blind as per P&ID. 4.2 Main Pipeline Pipeline facilities are schematically indicated in drawing no. 0001-00-03-01-5003. 5.0 5.1 PIPELINE ROUTE Pipeline Route Salient features of the surveyed pipeline route as per pipeline route map no. MAS/ GAIL/ CGJHPL/08/ RM-01/02/03/04, GAIL/ SKP/ GURGAON/ 2008/ R.M./01 (Rev.0), and survey report are tabulated herein below:

ENGINEERING DESIGN BASIS GAIL (INDIA) LTD NEW DELHI PIPELINE ENGINEERING

SPECIFICATION 0001-01-04-03-001

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SALIENT FEATURES OF RESPECTIVE PIPELINE ROUTE Sultanpur Spur Line Hayatpur Hayatpur Neemrana to Bhiwadi Manesar Gurgaon Size, OD ( Inch) 18 12 10 10 Length (Km) 85.28 9 5.4 11 Highest elevation Refer Survey Refer Refer Survey Refer Survey Report Survey Report Report above MSL (m) Report Lowest elevation above Refer Survey Refer Refer Survey Refer Survey Report Survey Report Report MSL (m) Report No. of River Crossing , 0 0 0 0 Width > 100 m No. of Road Crossing 3/2 0/2 0/0 1/0 (NH/SH) No. of Railway 3 0 0 0 Crossing No. of Canal Crossing 6 0 0 0 5.2 Terrain Details For Terrain details and Land use pattern refer survey reports prepared by M/s MASCON MSC PVT. Ltd and M/s SKP Projects P. Ltd. attached elsewhere in the bid document. 6.0 6.1 DESIGN DATA Main pipeline shall be designed for conditions as follows: PIPELINE DESIGN PARAMETER Description Value Sultanpur Neemrana Line 457.2 mm OD Bhiwadi/ Chopanki Tap-off Bhiwadi Line 323.9 mm OD Hayatpur to Manesar 273.1 mm OD Hayatpur to Gurgaon PRODUCT Natural Gas/ RLNG Design Pressure (Kg/ Cm2g) 99.93 2 Operating Pressure (Kg/ Cm g) 60-99 0 Maximum Design Temperature, C i. Above Ground Section -29 to 65.0 ii. Under Ground Section -29 to 45.0 Operating Temperature, 0 C 13 - 25 Economic Design Life, Years 35 Corrosion Allowance 0 Hayatpur to Gurgaon Design Pressure shall be 49 273.1 mm OD 2 Kg/cm g and Design Temp AG/UG (-) 29 to 65 / (-) 29 to 45. Rest other parameter shall be as above.
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All terminal facilities (equipment and associated piping) shall be designed for design and operating conditions given in the process package. 7.0 7.1 PIPELINE AND ASSOCIATED FACILITIES DESIGN General Pipeline and pipeline stations to be installed as a part of this project shall be designed and engineered in accordance with the standards/codes referred in section 3.0 of this document. 7.2 Pipeline 7.2.1 Pipeline shall be designed in accordance with requirements of ASME B 31.8 and OISD 141. The pipeline shall withstand all installation, testing and operating condition/ loads. All necessary calculations shall be carried out to verify structural integrity and stability of the pipeline for the combined effect of pressure, temperature, bending (elastic), soil/pipe interaction, external loads and other environmental parameters as applicable during all phases of work from installation to operation. Allowable stress limit shall be as per ASME B 31.8. Such calculations shall include, but are not limited to following: Buoyancy control and stability analysis for pipeline section to be installed in areas subjected to flooding/submergence. Unless specified, specific gravity of installation in such area shall be at least 1.2. Stress analysis at crossing of major rivers, rail and highway etc. Crossing analysis of rivers by HDD if applicable. Pipeline expansion and its effect on station piping (above ground/below ground).

7.2.2 Pipeline shall also be checked for adequacy against anticipated earthquake loading and any special measures such as increase in wall thickness/ grade/ select backfill etc. as required to ensure safety and integrity of the pipeline system shall be implemented. 7.2.3 Mainline shall be provided with bi-directional pigging facilities suitable for handling all types of pigs including intelligent pigs. 7.2.4 Pipeline and its associated facilities shall be designed using the applicable design code and as modified below. The pipeline shall be designed to meet the Location Class as defined in ASME B31.8, except as modified below.

ENGINEERING DESIGN BASIS GAIL (INDIA) LTD NEW DELHI PIPELINE ENGINEERING

SPECIFICATION 0001-01-04-03-001

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Location Class
All Class 1

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

Design Factor
0.5 0.6 0.72 0.5 0.6 0.5 0.5 0.6 0.5 0.5 0.5 0.5 0.4

Class 2

Class 3 Class 4 7.3 Station Piping

7.3.1 Station piping to be provided at terminals, intermediate stations, SV stations shall be designed in accordance with OISD 141/ASME B 31.8 and utility piping to be provided at these locations shall be designed in accordance with the provisions of ASME B 31.3. 7.3.2 All piping shall be designed for combined effects of pressure, weight and temperature during operating conditions without over stressing the piping, valves or equipment. All piping shall be adequately supported, guided or anchored so as to prevent undue vibration, deflection or loads on connected equipment such as filters, meters etc. 7.4 Materials Pipeline and its appurtenances shall be provided with carbon steel materials suitable for the intended service, as detailed in subsequent paragraphs 7.4.1 Line pipe for main line Line pipe shall conform to API 5L and Company specifications. Type of line pipe to be used shall be SEAMLESS/LSAW/ HSAW/EW.
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Sr. No.

LINE SIZE 18(457.2 mm) 12 (323.9 mm) 10 (273.1 mm)

GRADE

Class - I Class - II

Class - III

Class IV

1 2 3

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

6.5 6.4 6.4

7.9 6.4 6.4

9.3 7.9 6.4

11.7 9.5 7.8

7.4.2 Other Materials All other materials and equipments including scraper traps, flow tees, insulating joints, ball valves, plug valves, globe valves, check valves, pig signallers, flanges and fittings shall be carbon steel suitable for the service conditions and shall be compatible with the line pipe material. 7.5 External/ Internal corrosion coating 7.5.1 Pipeline to be installed below ground shall be protected against external corrosion by a combination of high integrity externally applied coatings and permanent impressed cathodic protection system. Externally applied coating shall be three layer side extruded polyethylene coating. 7.5.2 In addition, pipeline shall be provided with minimum 80 micron thick liquid epoxy internal coating conforming to ISO 15741/API RP 5L2. Extremities of pipe shall be free from coating over a length of 20 5 mm. 7.5.3 All above ground piping and structures shall be painted to prevent atmospheric corrosion. Painting of above ground piping and structures shall be as per specifications. Painting shall be suitable for normal corrosive environment/corrosive environment, as applicable, as defined in Painting Specification No. S-05-02-014 for all stations and terminals. 7.6 Insulating joints Insulating joints shall be provided to electrically isolate the buried pipeline from above ground pipeline. Insulating joints shall be monolithic type and shall allow smooth passage of pigs. Insulating joints shall be installed in above ground portion of the pipeline, immediately after the buried/aboveground transition at the scraper stations. Wherever pressure/ temperature transmitters are used on cathodically protective pipeline the same shall be electrically isolated by providing insulating joints/ flanges. 7.7 Pipeline Burial The pipeline shall be buried normally at a depth of 1.0 meter below natural ground level except river/ rail/ road/ canal/waterways crossing where minimum cover shall be as
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given below or as per the requirements of statutory/local authorities whichever is more stringent. Increased cover shall be provided at critical locations and crossings. Sl. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Location Industrial, commercial and residential area Rocky terrain Minor water crossing/ canal/ drain/ nala/ waterways HDD crossing of canals (below bed) River crossings for which scour depth is defined (below scour) Other River crossings (Bank width > 50m) (Below Bed) Other River crossings (Bank width < 50m) (Below Bed) Cased/uncased road crossing Cased railway crossing Drainage, ditches at roads/railway crossings Minimum Cover (m) 1.0 1.0 1.5 2.5 1.5 2.5 (For normal soil) 1.5 (For rocky strata) 1.5 1.2 1.7 1.2 1.5

11.0 Marshy land/Creek area

Additional soil cover other than specified above shall be provided at locations indicated by statutory/ local authorities or in areas likely to have an increased risk of impact damage or third party interference as per agreements between COMPANY and authorities. In case, any private dwelling, industrial building or place of public assembly falls within 15 m of pipeline, additional cover of minimum 300 mm shall be provided over and above the cover indicated in the above table. 7.8 Marshy Areas / Areas Prone to Flooding Wherever marshy areas/areas prone to flooding are encountered along the pipeline route, pipeline shall be provided with anti buoyancy measures viz. continuous concrete coating/ Geotextile gravel filled bags. Unless specified otherwise in AFC drawings, specific gravity of installation in such areas shall be at least 1.2. 7.9 Pipeline in common ROW The location of new underground pipeline, when running parallel to an existing underground pipeline in same ROU/ROW shall be laid at minimum clear distance of 5.0 m from the existing underground pipeline. This distance may be reduced to 3.0 m after
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assessment of construction methodology which do not result in unsafe conditions during construction. 7.10 Backfilling In normal cross-country areas, the pipeline trench shall be backfilled with excavated soil. Select rockfill/ slope breakers shall be provided in the trench in steep areas (slope generally 10% and more) to prevent erosion. In case of rivers/water bodies prone to scour and erosion, the safety cover shall be provided below the predicted scour level. In addition to the cover, anti buoyancy measures (concrete coating) shall be provided at river crossings. Contractor shall keep top 150 mm of excavated top soft soil (free of gravels) aside, which shall be back filled in the end as top layer. Select backfill shall be provided at approaches to terminal up to transition point (below ground/above ground) inside terminal. Select back fill shall also be provided as applicable for areas prone to seismic activity. Recommendation of Seismic Analysis Report should be considered for such special backfill. Pipeline route shall be examined to establish any drainage requirement in hilly terrain. In case required, the drainage shall be designed to prevent trench flooding during construction and protect the integrity of the installed pipeline following completion of all construction activities. In rocky areas, the trench bottom shall have sand/soft soil padding of 150 mm. After laying of pipeline, sand/soft soil padding shall be placed around and on top of the pipe so that thickness of compacted padding on top of pipe corrosion coating shall be at least 150 mm. Disposal of debris and surplus material to designated disposal areas or designated place(s), as the case may be and as directed by Engineer-in-charge shall be carried out. 8.0 8.1 OTHER TECHNICAL REQUIREMENTS Scraper Stations Scraper traps shall be provided at the Despatch terminals (Sultanpur) and Receiver Terminal at Neemrana. The scraper traps shall be bi-directional capable of handling intelligent pigs and other cleaning pigs. The launching and receiving barrels shall be designed in accordance with the requirements of ASME B 31.8 and its end closure shall be designed and fabricated according to ASME Section VIII, Div.1. Adequate arrangements for launching, retraction, handling and lifting of cleaning and instrumented pigs shall be provided at the scraper stations. Traps shall be accessible by walkway/road for movement of equipment, pigs etc. These stations shall be provided with access road from the nearest metalled road.
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Corrosion resistant coating shall be provided on the pipeline up to a minimum length of 500 mm after it comes aboveground / before it gets buried underground at terminals and scraper stations. The diameter of barrel of the launcher cum receiver shall be three nominal sizes larger than the pipeline nominal size. Center line elevation of scraper trap shall be at suitable height from grade level. Suitable arrangements shall be provided for handling & lifting of pigs. The piping system at the terminals and intermediate stations shall be designed to have sufficient flexibility to prevent pressure and thermal expansion or contraction from causing excessive stresses on the connected equipment. The piping shall be designed/fabricated as defined in clause 8.3. As far as possible, pipeline expansion shall be absorbed by allowing the scraper traps to move on supports. Installation of anchor block in the under ground pipeline is not permitted. If required adequate length of trench in approaches to stations shall be provided with a select backfill to ensure flexibility. 8.2 Sectionalising Valve Stations Sectionalising valve station shall be provided along pipeline route for isolating sections of pipeline as per ASME B 31.8 for: Limiting the hazard and damage from accidental discharge from pipeline system. Facilitating maintenance of pipeline system and Complying with the requirements of applicable codes.

The location of sectionalizing valves are indicated in PFD. The requirements of applicable codes taking consideration of terrain features, requirement of safety and operation etc. to be taken in to account while providing Sectionalizing Valves. Sectionalizing valve on the main pipeline shall be ball valves of full bore type, to allow smooth passage of cleaning and intelligent pigs. All valves installed at Intermediate facilities, block valve stations, scraper stations and pipeline sectionalizing valve stations shall be gas actuated/ hand operated and with butt welding ends. Sectionalizing and Station block valves shall be installed buried and provided with a stem extension in such a way that the center line of rim of the hand wheel on a horizontal shaft or center of actuator is at approximately 1.0 m above the finished ground level. Valve surface shall be provided with corrosion protection coating. Valve body vent and drain lines shall be extended and terminated above ground. The valve stations shall be located at a readily accessible location such as near road and shall be provided with an access road from the nearest all weather metalled road. The facilities within valve station shall be secured by a chain link fence enclosure with gate. The location of valve station shall be clear of overhead power lines. The provisions of remote operated feature shall be as per the operation and control
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philosophy to be adopted for the project. At locations, where valve stations are combined with CP/Repeater stations, the safe distance and statutory clearance as per standard shall be followed. 8.3 Piping

8.3.1 General This section describes the design requirements of piping applicable for Despatch station, intermediate pigging stations, sectionalizing valve stations and receiving station. All piping and equipment shall be designed as per ASME B 31.8. All piping materials shall be as per Piping Material Specification (PMS). Utility piping to be provided shall be designed in accordance with the provisions of ASME B 31.3. Design shall provide consideration for all loadings like weight, temperature etc., significantly affecting the pipe material stresses in addition to fluid pressure. 8.3.2 Piping flexibility/stress analysis All piping shall be designed for thermal expansion under start up, operating and shut down conditions without over stressing the piping, valves or equipment. Provisions for expansion shall normally be made with bends and offsets. All piping shall be adequately supported, guided or anchored so as to prevent undue vibration, deflection or loads on connected equipments. Equipments/ valves requiring periodical maintenance shall be supported in such a way that the valves and equipment can be removed with minimum temporary pipe supports. 8.3.3 Piping layout 8.4 Piping will be located above-ground wherever possible within the terminals. Piping shall be designed considering skin temperature of piping material under empty conditions as 65C or design temperature of pipeline whichever is higher. Piping stress analysis shall be carried out to determine allowable pipe movement and support requirements wherever felt necessary. Buried piping inside the terminal area will have a minimum depth of cover of 1.2 m. Where buried pipes come out of the ground, the underground coating on the pipe will continue for a distance of 500 mm above ground. Platforms, crossovers shall be provided for ease of operation and maintenance. Platform for filters shall be provided for maintenance/ operational access. Painting above ground piping and structures shall be as per specifications enclosed in the Bid package. Welding
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Welding shall be carried out in accordance with API 1104, specification for welding and welding charts. Butt welds shall be 100 % radio graphed / automatic UT for automatic welding, as applicable for all pipelines. For gas service all butt welds for process piping shall be 100% radiographed and for utility piping NDT requirements shall be as per specification no. S-05-02-12. 8.5 Hydrostatic Testing After installation, the entire pipeline system shall be hydrotested with inhibited water. The water shall tested, as applicable prior to using for hydrotesting. The minimum hydrostatic pressure in any section shall be as per ASME B 31.8 for gaseous hydrocarbon pipelines. The maximum hydrostatic test pressure at any location of the pipeline shall not exceed the pressure required to produce a hoop stress equal to 95% of SMYS of the pipe material based on minimum wall thickness in the test section. The test duration shall be minimum 24 hours. Hydrostatic testing of terminals shall be carried out separately. Terminals as well as other intermediate facilities shall be tested at 1.4 times the design pressure. The test duration shall be 6 hours. Mainline valves shall be installed after successful completion of hydrotesting. 8.6 Dewatering and swabbing Dewatering, swabbing and pre-commissioning operations shall be carried out after hydrotesting and prior to commissioning of the pipeline as per Project specifications. For gaseous hydrocarbon pipeline the line shall be dried. Swabbing shall be carried out prior to installation of Sectionalizing valves. After swabbing operation the pipeline sections shall be dried as per relevant specification enclosed with the tender. 8.7 Crossings All water crossing shall be installed by open cut. The requirement of HDD at any water crossing shall be finalized during detailed engineering. Wherever there is an evidence of bank erosion, the banks shall be protected by using gravel and boulders filled embankment mattresses of galvanized iron wire to be laid over the backfilled, compacted and graded banks. 8.7.2 Rail Crossing Pipeline at rail crossings shall be provided with casing pipe. The size of Casing pipe shall be 609.6 mm O.D. (24), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW (unless advised otherwise by concerned authorities) and shall be installed by boring/ jacking/ HDD/ ramming. The rail crossing shall comply with the requirements of API 1102 and Indian Railway Authorities. The crossing angle shall be as close to 90 as possible. It should be noted that the extent of casing pipe generally specified by Railways is 14.0 m beyond centerline of the outermost tracks on either side or 0.6 meter beyond the ROU limits of Railways on either side, whichever is more. Carrier pipe shall be electrically insulated from the casing pipe and casing ends shall be sealed using durable,
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8.7.1 Water Crossings

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electrically non-conducting materials. The crossing drawing shall be subject to approval of concerned Railway Authorities prior to implementation. 8.7.3 Road Crossing Road crossings shall comply with the requirements of API 1102 and the requirements of the concerned road authorities. Unless otherwise required by concerned Authorities, casing pipe shall not be used. However at national highway road crossings pipeline shall be provided with casing pipe, which shall extend min. 600 mm beyond Road ROW on either side. The casing pipe shall be installed by trenchless method like ramming/ boring/ jacking/ HDD /Micro Tunelling. Provision of casing at locations other than national highways shall be decided based on type of road crossing and as per requirements of local authorities if necessary. The casing pipe shall be 609.6 mm O.D. (24), 6.5 mm WT, API 5 L Gr. X70, LSAW/ HSAW. The crossing angle shall be as close to 90 as possible. Casing insulators and end seals shall be provided to ensure electrical isolation of carrier pipe and casing pipe. 8.7.4 Existing Pipeline Crossing The specific requirements of Owner/operator of existing pipeline shall generally be followed. The minimum clearance between the lines shall be 300 mm unless specified otherwise. 8.8 Valves Valve type Globe Ball Plug Check Typical application Throttling On/off, Isolation (on main line) On/off, Isolation (in the terminals) Uni-directional flow 8.8.1 Application of various types of valves shall be as follows:

All pipeline valves shall comply with the requirements of API 6D/ relevant PMS. Ball valves shall have primary metal seated design. In order to minimise potential leak sources, valves used in mainline shall be with butt-weld ends. Valve installed within the terminal to isolate the mainline/ pipeline shall also be provided with butt welding ends. However terminal valves shall be flanged ends. Flanges may be used where frequent access or removal of equipment is required. Wherever underground valves are provided, valves shall be provided with a stem extension in such a way that the centreline of the rim of the hand wheel on a horizontal shaft or centre of power actuator as approximately 1.0 m above the finished ground level. Minimum size of any tapping from the underground pipeline shall be 2" NB and shall be
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provided with an isolation ball valve located at a minimum distance from the pipeline. 8.9 Branch Connections All branch connections or side tap on the piggable lines wherever the branch line diameter is approx. 40% or more of the main line size, shall be provided with flow tees to enable smooth passage of all types of pigs. Flow tees for this purpose shall have an internal pipe housed in a tee. 8.10 Pipeline Bends In order to accommodate changes in vertical and horizontal alignment in piggable section of pipeline, elastic bends/cold field bends/hot formed long radius bends shall be used. Miter bends shall not be used for change in direction. Necessary design/ calculation for arriving Minimum Elastic Bend Radius shall be worked out by Contractor and shall be ratified by GAIL. Minimum bend radius shall be as follows: Minimum Bend Radius Pipeline Details 18, X-70, PSL-2 (thk. 6.5/7.9/9.3 mm) 12, X-60, (thk. 6.4/7.9/9.5 mm) 10, X-60, (thk. 6.4/ 7.8 mm) 8.11 Pig Signallers 8.11.1 Pig signallers shall be installed as a minimum at the following locations at each Launcher/ Receiver: On Pig launcher cum receiver One location on the line Hot Formed Cold Field LR Bend Bend Radius Radius R=27 D R=18 D R=18 D R=6D R=6D R=6D

8.11.2 Pig signaller shall be bi-directional type with trigger mechanism, suitable for maintenance with pipeline under operating pressure. 8.12 Specifications All procurement of materials shall be as per Piping Material Specification (PMS) and specifications indicated in PMS. ANNEXURE - A LIST OF CODES AND STANDARDS In addition to the codes/standards mentioned in para 3.0, the latest edition of the below listed equivalent codes and standards shall also be used for design of proposed pipeline. The listing includes, but is not limited to, the following:
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1. Line Pipes API 5L API 5L1 API 5LW 2. Valves API 6D API 602 ASTM A694 MSS-SP-6 MSS-SP-25 BS 5351 3. Flanges & Fittings MSS-SP-44 ANSI B16.5 ANSI 16.20 ASTM A105 ASTM A193 API 601 ANSI B16.9 ANSI B16.11 ANSI B16.26 ASTM A234 ASTM A694 MSS-SP-75
GAIL (INDIA) LTD NEW DELHI

Specification for Line pipe Recommended Practice for Railroad Transportation of Line pipe Recommended Practice for Transportation of Line pipe on Barges & Marine Vessels Specification for pipeline valves (Steel Gate, Plug, Ball and Check Valves) Compact Steel Gate Valves-Flanged, Threaded, Welding & Extended Body ends. Forgings, Carbon & Alloy steel for Pipe Flanges, Fittings, Valves & parts for High Pressure Transmission Service. Finishes for Contact Faces of connecting End Flanges of Ferrous Valves and Fittings. Standard Marking System for Valves, Fittings & Unions Steel Ball Valves for the Petroleum, Petrochemical and Allied Industries Steel Pipeline Flanges Pipe Flanges and Flanged Fittings Ring-joint Gaskets & Grooves for Steel Pipe Flanges Forgings, Carbon Steel for Piping Components Carbon & Alloy Steel Bolts & Studs for High Temperature Service Standard for Metallic Gaskets for Raised-Face Pipe Flanges & Flanged Connections Factory Made Wrought Steel Butt Welding Fittings Forged Fittings, Socket Welded & Threaded Butt Welding Ends Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Forgings, Carbon & Alloy Steel for Pipe Flanges, Fittings, Valves & Parts for High Pressure Transmission Service. Specification for High Test Wrought Butt Welding Fittings
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MSS-SP-97 PFI-ES-24 4. Testing & Welding ANSI/AWS D1.1 API 1104 AWS A3.0 AWS A5.1 AWS A5.5 ASTM E165 ASTM A370 ASTM E18 ASTM E23 ASTM E84 ASTM E92 ASTM E110 ASTM E709 MSS-SP-53 MSS-SP-54 MSS-SP-55

Integrally Reinforced Forced Branch Outley Fittings Socket Welding, Threaded and Butt Welding Ends. Pipe Bending Methods, Tolerances, Processes & Material Requirements Structural Steel Welding Standard for Welding Pipelines and Related Facilities Welding Terms and Definitions Welding Electrodes Specification for Low Alloy Steel Covered Arc Welding Electrodes Liquid Dye Penetrant Inspection of Pipeline Welds Standard Methods and Definitions for Mechanical Testing of Steel Products. Standard Hardness Test for Metals Standard for Impact Test for Metals Standard Test Method for Micro-hardness of Metals Standard Test Method for Vickers Hardness of Metallic Materials Standard Test Method Indentation Hardness for Metallic Materials by Portable Hardness Testers Standard Guides for Magnetic Particle Examination Quality Standard for Steel Casting & ForgingMagnetic Particle Method Quality Standard for Steel Casting & ForgingRadiographic Examination Quality Standard for Steel Castings & ForgingsVisual Method.

5. Surface Preparation, Painting and Coating SIS-05-59 SSPC-SP-01 SSPC-SP-03 Pictorial Surface Preparation Standards for Painting Steel Surfaces Solvent Cleaning Power Tool Cleaning
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SSPC-SP-05 SSPC-SP10 NACE No.2 SSPC-PA-02 ASTM E12 ASTM-G6

Joint Surface Preparation Standard: White Metal Blast Cleaning Structural Steel Painting Council Joint Surface Preparation Standard - Near-White Metal Blast Cleaning Measurement of Dry Paint Thickness and Magnetic Gauges Measurement of Pipeline Dry Film Coating Thickness Abrasion Resistance of Pipeline Coating

ASTM G8 NACE-RP-0274 IEC 454 2

Cathodic Disbonding of Pipeline Coatings High Voltage Electrical Inspection of Pipeline Coatings Prior to Installation Specification for Pressure-Sensitive Electrical Purposes Adhesive Tapes for

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

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PIPING MATERIAL SPECIFICATION

SPUR LINES OF CHAINSA JHAJJAR PIPELINE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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CONTENTS
SL NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 TABLE - 1 TABLE - 2 SCOPE CODES AND STANDARDS MATERIAL SPECIFICATIONS CLASS DESIGNATION CODES PIPELINE PIPING FITTINGS BENDS FLANGES GASKETS BOLTING THREAD SERALANT VALVES QUICK OPENING END CLOSURE HYDROTESTING VENT AND DRAINS PIPELINE SPECIALITY ITEMS PIPE WALL THICKNESS DETAILS FOR MAINLINE SPUR LINE PRESSURE/TEMP & OTHERS DESIGN CONDITIONS FOR VARIOUS PIPING CLASSES DESCRIPTION

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

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1.0

SCOPE It is propose to install a Natural gas pipe lines from Sultanpur Neemrana, Bhiwadi / Chopanki TOP to Bhiwadi, Hayatpur Manesar and Hayatpur - Gurgaon in Haryana / Rajasthan states to initially cater the demand of consumers in Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar, Khandsa and Gurgaon regions. The proposed Natural gas pipeline shall be of 457 mm (18) OD, approximately 85.28 km long; 323.9 mm (12) OD, approximately 9 km long and 273.1 mm (10) OD, approximately 16.40 km. The scope shall include piping and tap-off points at various locations of ChainsaJhajjar spur pipeline, that is for Bhiwadi, Gurgaon, Manesar, dispatch terminals, Sectionalising Valve stations, Tap-off terminals, receiving terminals, Spur line and various CGSs. This document covers minimum requirements for various piping materials necessary for the design of the piping/ pipeline and metering skid facilities coming under the project. This specification shall be read in conjunction with various Codes and Standards of latest edition, as applicable.

1.1

2.0

CODES AND STANDARDS Pipeline and pipeline terminal facilities envisaged as part of this project shall be designed and engineered primarily in accordance with the provisions of the latest edition of the following codes: (i) ASME B31.8 Gas Transmissions and Distribution for pressure Piping System

2.1

(ii) (iii)
2.2 2.3 2.4 3.0

ASME B31.3 OISD Standard 141

Chemical Plant and Petroleum Refinery Piping Design and Construction Requirements for Cross Country Hydrocarbon Pipelines.

All codes, standards and specifications referred herein shall be the latest edition of such documents. For sake of brevity the initials of the society to which the codes are referred may be omitted in the specifications, for example, B16.5 is a code referring to ASME; A106 is a code referring to ASTM. In addition, GAIL specifications and standards for various piping and pipeline materials shall also be applicable. MATERIAL SPECIFICATIONS Individual piping class has been generally designed to cover a set of service operating within pressure-temperature consideration as per ASME B16.5/ B16.34 or part of it. Deviations of material from class specifications may occur due to specific design conditions and/ or availability. These deviations are permissible if they equal or better the individual class requirements and shall be subjected to approval on case-to-case basis. All materials shall conform to detailed specifications / data sheets for items as applicable.

4.0

CLASS DESIGNATION CODE The piping class designation shall generally consist of three digits made up of a letter, number, letter e.g. A1A, A3A, A4A, B1A, D1A, E1A, etc. as follows: First letter indicates ASME Class rating e.g.
PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI SPECIFICATION 0001-01-05-02-001 REV-0 Page 3 of 68

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

The last letter indicates type of material. E.g. A Carbon steel.


5.0 5.1 6.0 6.1 PIPELINE Line pipe material grade and wall thickness details are indicated in Table-I. PIPES Carbon steel pipe shall be made by open hearth, electric furnace or basic oxygen process only. The steel used shall be fully killed and made with fine grain structure. The grade and wall thickness of various sizes of pipes shall be as per piping material specification for the applicable class. Pipe dimensions shall be in accordance with ASME B 36.10 for carbon steel ASTM standard pipes; & API 5L for carbon steel API 5L grade pipes. All pipe threads shall conform to American Standard taper as per ASME B1.20.1 NPT, unless otherwise specified. For butt weld end, bevel shall be in accordance with API specification 5L or ASME B 16.25 as applicable. FITTINGS Fully killed carbon steel shall be used in the manufacture of fittings. The fitting shall have carbon equivalent not exceeding 0.45, based on check analysis. Threaded joints, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT. Dimensions of socket welded/ screwed fittings shall conform to ASME B 16.11. Swage shall be as per BS 3799. Dimensions of steel butt welded fittings shall be as per ASME B 16.9. Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its thickness. Butt welding ends shall conform to API specification 5L or ASME B 16.25 as applicable. In case of difference in thickness of matching ends, requirements of ASME B 31.8 shall apply. Integrally reinforced forged branch fittings such as Sockolet, Weldolet etc. shall be as per MSS-SP97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturers standard. Fittings thickness tolerances shall match pipe thickness tolerance. BENDS
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6.2 6.3

6.4

7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 8.0

8.1

Unless otherwise specified for process piping, elbow of radius R Minimum Bend Radius D = Specified Outside Diameter

1.5 D shall only be used.

8.2

In order to accommodate changes in vertical and horizontal alignment in piggable section of pipeline, Elastic bends/ Cold field bends/ Hot formed long radius bends shall be used. Long Radius Bend shall be used only when indicated in the drawing. Miters shall not be used. FLANGES Pressure Temperature rating of flanges shall conform to B16.5/ MSS-SP44/ B16.47 Series A, as applicable. Dimensions of flanges shall be in accordance with B16.5/ MSS-5P44/ B16.47 Series A, as applicable. Neck of weld neck (WN) flanges shall suit pipe bore and thickness. Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness. Threads for screwed flanges, if used, shall conform to American Standard taper as per ASME B 1.20.1 NPT. Sizes for blind flanges shall be indicated by nominal pipe size. Unless specified otherwise in Piping Material Specification the flange face finish shall be as per ASME B16.5. Butt welding ends of WN flanges shall conform to ASME B 16.25. Spectacle blind/ spacer & blinds shall be in accordance with ASME B16.48/ manufacturers standard. Two jack screws, 1800 apart shall be provided in spectacle blind or spacer & blind assemblies as per GAIL standards. GASKETS Spiral wound metallic gasket with compressed asbestos filler shall conform to ASME B16.20/ API 601. All spiral wound gaskets shall be provided with stainless steel centering ring. Spiral wound gasket shall be self-aligning type. BOLTING & THREADS Nuts for stud bolts shall be American Standard Hexagon Heavy Series and double chamfered. Dimension and tolerances for stud bolts and nuts shall be as per ASME B18.2.1 and 18.2.2 with full threading to ASME B 1.1 Class 2A thread for bolts and Class 2B for nuts. Diameter and length of stud bolts shall be as per ASME B 16.5/ ASME B16.47 with full threading. Threads for nuts shall be as per ASME B 1.1 Nuts for stud bolts dia to 1
GAIL (INDIA) LTD NEW DELHI

8.3 9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 10.0 10.1 10.2 11.0 11.1 11.2

11.3

UNC-2B
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PIPING MATERIAL SPECIFICATION

Nuts for stud bolts dia 1 % to 3 11.4

8UN-2B

Threads for stud bolts shall be as per ASME B 1.1, as follows: Stud bolts dia to 1 Stud bolts dia 1 % to 3 : : UNC-2A 8UN-2A

11.5 11.6 12.0 12.1 13.0 13.1 13.2

Threads for threaded pipe, fitting, flanges and valve shall be in accordance with B1.20.1 taper threads, unless specified otherwise. Heads of jack screws shall be heavy hexagonal type. Jack screw end shall be rounded. Stud bolts shall be fully threaded with two hexagonal nuts. THREAD SEALANT Threaded joints shall be made with 1 wide PTFE jointing tape. VALVES Valve ends shall be as per valve data sheets for various piping class. Sectionalizing valves, Block valves and other isolation valves installed on the main pipeline shall be ball valves with butt welding ends. All inline isolation valves on the mainline (pipeline) shall be full bore valves to allow smooth passage of cleaning as well as intelligent pigs. All buried valves shall be provided with stem extension, sealant, vent/drain and shall have butt welded ends as per relevant specification/ data sheet. Flange dimensions and face finish of flanged end valves shall conform to clause 9.0 of this specification. Butt welding ends of Butt Welded valves shall conform to ASME B 16.25. Face to face and end to end dimensions shall conform to applicable standards. Valves shall conform to following standards unless specified otherwise in piping material specification for various piping class. Flanged/ Socket Welded end valves (1 and below) Design STD. for Process lines Gate Valves Globe Valves Ball Valves Plug Valves : : : : API 602 BS 5352 BS 5351 BS 5353

13.3 13.4 13.5 13.6 13.7

Flanged/ Butt Welded end valves (2 and above) Design STD. for Process Lines Gate Valves Globe Valves Check Valves
GAIL (INDIA) LTD NEW DELHI

: : :

API 6D BS 1873 API 6D


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PIPING MATERIAL SPECIFICATION

Ball Valves Plug Valves 13.8

: :

API 6D API 6D

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

13.8.1 Gate Valves For ANSI class 150 and 300 For ANSI class 600 13.8.2 Globe Valves For ANSI class 150, 300, 600 and 900 - Hand Wheel operated for all size 13.8.3 Ball valves & Plug Valves For all ANSI class 13.8.4 Gas Actuated Valves Gas actuated valves shall be as per P & IDs. The actuator shall have provision for remote operation as per P & IDs. All gas actuated valves shall have additional provision of hand wheel operation. 14.0 QUICK OPENING END CLOSURE Quick opening end closure to be installed on scraper traps shall be designed in accordance with Section VIII of ASME Boiler and Pressure Vessel Code and equipped with safety locking devices in compliance with Section VIII, division 1. UG-35.2 of ASME Boiler and Pressure Vessel Code. 15.0 HYDROTESTING VENTS AND DRAINS In terminal piping, high point vents and low point drains required for the purpose of hydrotesting shall be of size 0.75. These vents & drains shall consist of gate valves with blind flange assembly. 16.0 PIPELINE SPECIATLITY ITEMS Pipeline specialty items viz, scraper traps, Barred tees, insulating joints, LR bends etc. shall be as per specifications attached elsewhere. : Wrench operated for size 4 NB. Gear operated for size 6 NB. : : Hand wheel operated for size 12 NB. Gear operated for size 14 NB. Hand wheel operated for size 10 NB. Gear operated for size 12 NB

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 7 of 68

Sl. No.
Class I Class II

SECTION

TPIPE DIA (INCH)

MATERIAL (API 5L)

METHOD OF MANUFACTURE

W.T. (mm)

GAIL (INDIA) LTD NEW DELHI

LINE PIPE 18 LSAW, HSAW, SEAMLESS, EW SEAMLESS ,EW SEAMLESS ,EW SEAMLESS ,EW 12 10 10 X 60, PSL-2 X 60, PSL-2 X 60, PSL-2 X 70, PSL-2 6.5 6.4 6.4 6.4

Class III

Class IV

1.

Sultanpur Nimrana Pipe line

7.9 6.4 6.4 6.4

9.3 7.9 6.4 6.4

11.7 9.5 7.8 TABLE -1 6.4

2.

Bhiwadi/Chopanki TOP Bhiwadi Spur Line

3.

Spur line Hayatpur - Manesar

PIPING MATERIAL SPECIFICATION

3.

Spur Line Hayatpur - Gurgaon

SPECIFICATION

0001-01-05-02-001

REV-0 Page 8 of 68

Class D1A

Service Hydrocarbon Gas

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

C.A. (mm) 1.5

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

Design Code ASME B 31.8 / OISD 141

B1A

Hydrocarbon Gas

49.0

65

1.5

ASME B 31.8 / OISD 141/ 226

A1A

Hydrocarbon Gas

19

65

1.5

ASME B 31.8 / OISD 141 / 226

A3A J2A A93A

Utilities Potable Water Fire Water

10.5 10.5 18.9

65 65 65

1.5 0 1.5

ASME B 31.3 ASME B 31.3 ASME B 31.3

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 10 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

A1A, 150 # CARBON STEEL 1.5 MM NON IBR

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

SERVICE : NON CORROSIVE PROCESS - FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AMMONIA, STEAM & GAS CONDENSATE (NON- IBR), UTILITIES (WATER, INST, AIR, NITROGEN, CARBON DIOXIDE) AND LUBE OIL BEFORE THE FILTER. NOTES 1. 2. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY MPI 3. 4. 5. 6. 7. : : ALL BUTT WELDS SOCKET WELDS 100% 100%

PIPING DESIGN AS PER ASME B 31.8 & OISD 226. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES. ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. FOR VALVES, REFER RESPECTIVE VALVE DATA SHEETS. FOR HANDLE PROJECTION REFER STD. DRG-S-05-01-007. SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS SIZE ALL 1.5 & BELOW 2.0 & ABOVE DRAINS ON LINES 1.5 ON LINES 2.0 VENTS ON LINES 1.5 ON LINES 2.0 TEMP. CONN PRESS. CONN 1.5 0.75 DESCRIPTION FLANGED TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD.S-05-01-003 AS PER P&ID OR 0.75 REFER STD.S-05-01-004 REFER GAIL STD S-05-01-003 AS PER P&ID OR 0.75 REFER STD.S-05-01-004
FLANGED, INSTALLATION AS PER GAIL STD S-05-01-005. SW NIPPLE WITH GATE VALVE TO SPEC AS PER

STD.S-05-01-006 SPECIFICATION 0001-01-05-02-001 REV-0 Page 11 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

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

T T T T T S S S 2.000 2.500 T S S S S 3.000 3.500 T T S S S S 4.000 5.000 T T W S S S S 6.000

T T T W W S S S S 8.000

T T T T W W S S S S 10.00

T T T 0.750 T T T 1.000 1.250 T T T 1.500

T 0.500

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

BRANCH PIPE (SIZE IN INCHES)

RUN PIPE (SIZES IN INCH) A1A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 12 of 68

BRANCH PIPE (SIZE IN INCHES)

CODE
F H P R S

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS T W I X L TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Item Type

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

Pipe Group (A1A) PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE NIPPLE NIPPLE Flange Group (A1A) FLNG.WN FLNG.WN FLNG.BLIND PLNG.BLIND FLNG.FIG8 00.500 02.000 00.500 02.000 00.500 01.500 24.000 01.500 24.000 01.500 M M B-16.5 B-16.5 B-16.5 B-16.5 B-16.48 ASTM A 105 ASTM A 105 (CHARPY) ASTM A 105 ASTM A105 (CHARPY} ASTM A 105 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH 00.500 01.000 02.000 03.000 04.000 06.000 8.000 16.000 20.000 00.500 01.000 00.750 01.500 02.000 03.000 04.000 06.000 14.000 18.000 20.000 00.750 01.500 S160 XS XS STD STD STD 6.4 6.4 7.1 M M B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 API 5L API 5L API 5L B 36.10 B 36.10 ASTMA 106 GR.B ASTMA 106 GR.B ASTMA106 GR.B (CHARPY) ASTMA106 GR.B (CHARPY) ASTMA106 GR.B (CHARPY) ASTMA106 GR.B (CHARPY) API 5L GR.B PSL2 API 5L GR.B PSL2 API 5L GR.B PSL2 ASTMA 106 GR.B ASTMA 106 GR.B PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SAW BE, SAW PBE, SEAMLESS PBE, SEAMLESS

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 13 of 68

FLNG.FIG8 SPCR &BLIND Fitting Group (A1A) ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL T.EQUAL T.RED T.RED T.RED REDUC.CONC REDUC.ECC SWAGE.CONC SWAGE.ECC CAP CAP CAP CPLNG.FULL CPLNG.FULL CPLNG-HALF CPLNG.HALF

02.000 10.000

08.000 24.000

B-16.48 B-16.48

ASTM A105 (CHARPY) ASTM A105 (CHARPY)

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

00.500 01.000 02.000 00.500 01.000 02.000 00.500 01.000 02.000 00.500 01.000 02.000 02.000 02.000 00.500 00.500 00.500 01.000 02.000 00.500 01.000 00.500 01.000

0..750 1.500 24.000 00.750 01.500 24.000 00.750 01.500 24.000 00.750 01.500 24.000 24.000 24.000 03.000 03.000 00.750 01.500 24.000 00.750 01.500 00.750 01.500 M M, M M,M M,M M,M M,M M M

B-16.11 B-16.11 B-16.9 B-16.11 B-16.11 B-16.9 B 16.11 B 16.11 B-16.9 B-16.11 B-16.11 B-16.9 B-16.9 B-16.9 BS-3799 BS-3799 B-16.11 B-16.11 B-16.9 B-16.11 B-16.11 B-16.11 B-16.11

ASTM A 105 ASTM A 105 ASTM A 234,GR. WPB (CHARPY) ASTM A 105 ASTMA 105 ASTM A234,GR. WPB (CHARPY) ASTM A 105 ASTM A 105 ASTM A234,GR.WPB (CHARPY) ASTM A 105 ASTMA 105 ASTM A234,GR. WPB (CHARPY) ASTM A234,GR. WPB (CHARPY) ASTM A234,GR. WPB (CHARPY) ASTM A 105 (CHARPY) ASTM A 105 (CHARPY) ASTMA 105 ASTMA 105 ASTM A234,GR. WPB (CHARPY) ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105

SW, 6000 SW, 3000 BW, 1.5D SW, 6000 SW, 3000 BW, 1.5D SW, 6000 SW, 3000 BW SW, 6000 SW, 3000 BW BW BW PBE PBE SCRF, 6000 SCRF, 3000 BW SW, 6000 SW, 3000 SW, 6000 SW, 3000 SPECIFICATION 0001-01-05-02-001 REV-0 Page 14 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

CPLNG.LH CPLNG.LH CPLNG.RED CPLNG.RED Olet Group (A1A) SOCKOLET SOCKOLET WELDOLET

00.500 01.000 00.500 01.000

00.750 01.500 00.750 01.500

B-16.11 B-16.11 B-16.11 B-16.11

ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105

SW, 6000 SW,3000 SW, 6000 SW, 3000

00.500 01.000 02.000

0.750 01.500 10.000 M, XXS

MSSSP97 MSSSP97 MSSSP97

ASTM A 105 ASTM A 105 ASTMA 105 (CHARPY)

SW, 6000 SW, 3000 BW

Valves Group (A1A) VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 105, TRIM-STELLITED, STEM13%CR. STEEL BODY-ASTM A 105,TRIM-STELLITED, STEM13%CR STEEL BODY-ASTMA 105,TRIM-STELLITED SW,800, 3000,B16.11 SW,800, 3000,B16.11 SW,800, 3000, B16.11

VLV.GLOBE

00.500

01.500

BS-5352

VLV.CHECK

00.500

01.500

BS-5352

Bolt Group (A1A) BOLT.STUD 00.500 24.000 B18.2 BOLT: 193 GR.B7,NUT: A194 GR. 2H

Gasket Group (A1A) GASKET 00.500 24.000 B16.20ANSI B 16.5 SP,WND, SS316+CAF SPIRAL, 150

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 15 of 68

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 16 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

A3A, 150 # CARBON STEEL 1.5 MM NON IBR

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

SERVICE : NON CORROSIVE UTILITIES (ABOVE GROUND) COOLING WATER, INERT GAS, INSTRUMENT AIR, CONDENSATE NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. NDT REQUIREMENT AS PER GAIL STANDARD S-05-02-012

2.

3. FOR VALVES REFER VALVE DATA SHEET SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS SIZE ALL 1.5 & BELOW 2.0 & ABOVE DRAINS ON LINES 1.5 ON LINES 2.0 VENTS ON LINES 1.5 ON LINES 2.0 TEMP. CONN PRESS. CONN 1.5 0.75 DESCRIPTION FLANGED TO BE KEPT MINIMUM SW COUPLING 3000 # BUTT WELDED REFER GAIL STD.S-05-01-003 AS PER P&ID OR 0.75 S-05-01-004 REFER GAIL STD S-05-01-003 AS PER P&ID OR 0.75, S-05-01-004 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005
SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.

S-05-01-006

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 17 of 68

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

T T T T T T T 1.000 1.250 T T T 1.500 T T H H H 2.000 2.500 P H H H H 3.000 3.500 P P H H H H 4.000 5.000 P P P H H H H 6.000

T 0.500

T T 0.750

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

BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)


(A3A) REV-0 Page 18 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

CODE
F H P R S

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS T W I X L TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Item Type

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

Pipe Group (A3A) PIPE PIPE NIPPLE 00.500 02.000 00.500 1.50 06.000 01.50 HVY HVY HVY IS-1239I IS-1239I IS-1239I IS-1239 (BLACK) IS-1239 (BLACK) IS-1239 (BLACK) PE, C. WELDED PE, C. WELDED PE, C. WELDED

Flange Group (A3A) FLNG.SW FLNG.SO FLNG.BLIND FLNG.BLIND FLNG.FIG8 FLNG.FIG8 00.500 02.000 00.500 2.00 00.500 02.000 01.500 06.000 01.500 6.00 01.500 06.000 M B-16.5 B-16.5 B-16.5 B-16.5 B-16.48 B-16.5 ASTM A 105 ASTM A 105 (CHARPY) ASTM A 105 ASTM A105 (CHARPY} ASTM A 105 ASTM A105 (CHARPY) 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH 150, RF/125AARH

Fitting Group (A3A) ELBOW.90 ELBOW.90 00.500 02.00 01.500 06.00 STD B-16.11 B-16.9 ASTM A 105 ASTM A 234 GR. WPB (CHARPY) ASTM A 105 ASTM A 234 GR. WPB (CHARPY) ASTM A 105 SW,3000 BW, 1.5D

ELBOW.45 ELBOW.45 T.EQUAL

00.500 02.000 00.500

01.50 06.000 01.50 STD

B-16.11 B-16.9 B 16.11

SW, 3000 BW, 1.5D SW, 3000 SPECIFICATION 0001-01-05-02-001 REV-0 Page 19 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

T.EQUAL T.RED T.RED REDUC.CONC REDUC.ECC SWAGE.CONC SWAGE.ECC CAP CAP CPLNG.FULL CPLNG-HALF CPLNG.LH CPLNG.RED UNION

02.00 00.500 02.000 02.000 02.000 00.500 00.500 00.500 02.000 00.500 00.500 00.500 00.500 0.50

06.00 01.500 06.00 06.000 06.000 03.000 03.000 01.50 06.00 01.50 01.50 01.50 01.50 01.500

STD

B 16.11 B-16.11

ASTM A 234 GR. WPB (CHARPY) ASTM A 105 ASTM A 234 GR. WPB (CHARPY) ASTM A234,GR. WPB (CHARPY) ASTM A234,GR. WPB (CHARPY) ASTM A 105 (CHARPY) ASTM A 105 (CHARPY) ASTMA 105 ASTM A234,GR. WPB (CHARPY) ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105

BW SW, 3000 BW BW BW PBE PBE SCRF, 3000 BW SW, 3000 SW, 3000 SW, 3000 SW, 3000 SW, 3000

STD STD,STD STD,STD STD,STD STD,STD

B-16.9 B-16.9 B-16.9 BS-3799 BS-3799 B-16.11

STD

B-16.9 B-16.11 B-16.11 B-16.11 B-16.11 BS-3799

Valves Group (A3A) VLV.GATE 00.250 01.500 API-602 BODY-ASTM A 105, TRIM-STELLITED, STEM13%CR. STEEL BODY-ASTM A 216, WCB, TRIMSTELLITED, STEM13%CR. STEEL BODY-ASTM A 105,TRIM-STELLITED, STEM13%CR STEEL BODY-ASTM A 216, WCB, TRIMSTELLITED, STEM13%CR. STEEL BODY-ASTMA 105,TRIM-STELLITED BODY-ASTM A 216, GR. WCB, TRIM 13% CR. SREEEL SW,800, 3000,B16.11 FLGD, 150, B 16.5, RF/125AARH SW,800, 3000,B16.11 FLGD, 150, B 16.5, RF/125AARH SW,800, 3000, B16.11 FLGD, 150, B 16.5, RF/125AARH

VLV.GATE

02.00

24.00

API-600

VLV.GLOBE

00.25

01.500

BS-5352

VLV.GLOBE

02.00

16.00

BS-1873

VLV.CHECK VLV.CHECK

00.250 02.00

01.500 24.00

BS-5352 BS 1868

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 20 of 68

VLV.BALL

00.500

16.00

BS-5351

BODY-ASTM A 105,A 216 GR. WCB TRIMBODY SEAT - RPTFE BODY-ASTM A 216 GR., WCB, TRIM- 13% CR. STEEL

FLGD, 150, , B 16.5, RF/125AARH WAFL, 150, B16.5 WAF/125AARH

VLV.BTRFLY

03.500

24.00

BS-5155

Bolt Group (A3A) BOLT.STUD 00.500 6.000 B18.2 BOLT: A 307, GR. B, NUT: A 563 GR.B

Gasket Group (A3A) GASKET 00.500 6.000 B16.21ANSI B 16.5 IS-2712- GR.-W/3 RING, 150, 2 MM

TRAP/ STRAINER GROUP (A3A) TRP 00.500 1.50 MANFS STD MANUF STD MANUF STD M MANUF STD B:A105, T:13%CR, S:SS304 FLGD, THRMDNMC, 150, RF/125AARH CONETYPE, 150, FF/125 AARH SW, Y-TYPE, 800

TRP

01.500

6.000

B:A285GR.C; INT: SS304

TRP

00.500

1.500

B:A105; INT: SS304

TRP

02.00

6.000

B:A234GR. WPB; INT: SS304

BW, T - TYPE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 21 of 68

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 22 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

(B1A), 300 # CARBON STEEL 1.5 MM NON IBR

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

SERVICE
NON CORROSIVE PROCESS- FLAMMABLE / NON FLAMMABLE, NON LETHALHYDROCARBONS, AROMATICS, AMMONIA, SWEET GAS, FLUSHING OIL AND OTHER UTILITIES -MP CONDENSATE, INSTRUMENT AIR, PLANT AIR, NITROGEN, AMMONIA GAS ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY MPI 3. 4. 5. 6. : : ALL BUTT WELDS SOCKET WELDS 100% 100%

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226 FLANGES OF SIZE 22 SHALL BE AS PER MSS-SP-44. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES. ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

7.

SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS SIZE ALL 1.5 & BELOW 2.0 & ABOVE DRAINS VENTS ON LINES 1.5 ON LINES 2.0 ON LINES 1.5 ON LINES 2.0 TEMP. CONN PRESS. CONN 1.5 0.75 DESCRIPTION FLANGED, TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD.S-05-01-003 AS PER P&ID OR 0.75; GAIL STD. S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75. S-05-01-004 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S05-01-006

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REV-0 Page 23 of 68

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40

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

BRANCH PIPE (SIZE IN INCHES)

36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

10.000

12.000

14.000

16.000

18.000

(B1A)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

20.000

0.500 0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

BRANCH PIPE (SIZE IN INCHES)


REV-0 Page 24 of 68

38

38

CODE
F H P R S

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Size (Inch) Upper Size (Inch) Sch./ Thk T W I X L TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Item Type Pipe Group (B1A) PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE NIPPLE NIPPLE

Dim. STD

Material

Description

00.500 01.000 02.000 03.000 04.000 08.000 10.000 12.000 14.000 16.000 18.000 20.000 00.500 01.000

00.750 01.500 02.000 03.000 06.000 08.000 10.000 12.000 14.000 16.000 18.000 20.000 00.750 01.500

S160 XS XS STD STD 7.9 9.3 10.3 11.1 12.7 14.3 15.9 M M

B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 API 5L API 5L API 5L API 5L API 5L API 5L API 5L B 36.10 B 36.10

ASTMA 106 GR.B ASTMA 106 GR.B ASTMA106 GR.B (CHARPY) ASTMA106 GR.B (CHARPY) ASTMA106 GR.B (CHARPY) API 5L GR.B PSL2 API 5L GR.B PSL2 API 5L GR.B PSL2 API 5L GR.B PSL2 API 5L GR.B PSL2 API 5L GR.B PSL2 API 5L GR.B PSL2 ASTM A 106 GR.B ASTM A 106 GR.B

PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SAW BE, SAW BE, SAW PBE, SEAMLESS PBE, SEAMLESS

Flange Group (B1A) FLNG.SW 00.500 FLNG.WN FLNG.WN FLNG.BLIND FLNG.BLIND FLNG.FIG8 02.000 18.000 00.500 02.000 00.500

01.500 16.000 20.000 01.500 20.000 01.500

M M M

B-16.5 B-16.5 B-16.5 B-16.5 B-16.5 B-16.48

ASTM A 105 ASTM A 105 (CHARPY) ASTM A 105 (CHARPY) ASTM A 105 ASTM A105 (CHARPY} ASTM A 105

300, RF/125AARH 300, RF/125AARH 300, RF/125AARH 300, RF/125AARH 300, RF/125AARH 300, RF/125AARH REV-0 Page 25 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

FLNG.FIG8 SPCR &BLIND

02.000 10.000

08.000 20.000

B-16.48 B-16.48

ASTM A105 (CHARPY) ASTM A105 (CHARPY)

300, RF/125AARH 300, RF/125AARH SW, 6000 SW, 3000 BW, 1.5D BW, 1.5D SW, 6000 SW, 3000 BW, 1.5D BW, 1.5D SW, 6000 SW, 3000 BW BW SW, 6000 SW, 3000 BW BW BW BW BW BW PBE PBE REV-0 Page 26 of 68

Fitting Group(B1A) ELBOW.90 00.500 ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL T.EQUAL T.EQUAL T.RED T.RED T.RED T.RED REDUC.CONC REDUC.CONC REDUC.ECC REDUC.ECC SWAGE.CONC SWAGE.ECC 01.000 02.000 18.000 00.500 01.000 02.000 18.000 00.500 01.000 02.000 18.000 00.500 01.000 02.000 18.000 02.000 18.000 02.000 18.000 00.500 00.500

0..750 1.500 16.000 20.000 00.750 01.500 16.000 20.000 00.750 01.500 16.000 20.000 00.750 01.500 16.000 20.000 16.000 26.000 16.000 20.000 03.000 03.000 M, M M, M M,M M,M M,M M,M M,M M,M M M M M M M

B-16.11 B-16.11 B-16.9 B- 16.9 B-16.11 B-16.11 B-16.9 B 16.9 B 16.11 B 16.11 B-16.9 B 16.9 B-16.11 B-16.11 B-16.9 B 16.9 B-16.9 B-16.9 B-16.9 B 16.9 BS-3799 BS-3799

ASTM A 105 ASTM A 105 ASTM A 234,GR. WPB CHARPY) ASTM A 234,GR. WPB CHARPY) ASTM A 105 ASTM A 105 ASTM A234, GR. WPB CHARPY) ASTM A234, GR. WPB CHARPY) ASTM A 105 ASTM A 105 ASTM A234,GR.WPB (CHARPY) ASTM A234,GR.WPB (CHARPY) ASTM A 105 ASTM A 105 ASTM A234,GR. WPB(CHARPY) ASTM A234,GR. WPB(CHARPY) ASTM A234,GR. WPB(CHARPY) ASTM A234,GR. WPB(CHARPY) ASTM A234,GR. WPB(CHARPY) ASTM A234,GR. WPB(CHARPY) ASTM A 105 (CHARPY) ASTM A 105 (CHARPY)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

CAP CAP CAP CAP PLUG PLUG CPLNG.FULL CPLNG.FULL CPLNG-HALF CPLNG.HALF CPLNG.LH CPLNG.LH CPLNG.RED CPLNG.RED

00.500 01.000 02.000 18.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000

00.750 01.500 16.000 20.000 00.750 01.500 00.750 01.500 00.750 01.500 00.750 01.500 00.750 01.500 M M

B-16.11 B-16.11 B-16.9 B 16.9 B 16.11 B 16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11

ASTM A 105 ASTM A 105 ASTM A234,GR. WPB (CHARPY) ASTM A234,GR. WPB (CHARPY) ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105

SCRF, 6000 SCRF, 3000 BW BW SCRM, 6000 SCRM, 3000 SW, 6000 SW, 3000 SW, 6000 SW, 3000 SW, 6000 SW,3000 SW, 6000 SW, 3000

O let group(B1A) SOCKOLET 00.500 SOCKOLET WELDOLET 01.000 02.000

0.750 01.500 10.000 M, XXS

MSS-SP97 MSS-SP97 MSS-SP97

ASTM A 105 ASTM A 105 ASTMA 105 (CHARPY)

SW, 6000 SW, 3000 BW

Valves Group (B1A) VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR. STEEL BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% CR. STEEL BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% CR. STEEL BODY-ASTMA 105,TRIM-STELLITED BODY-ASTM A 216 GR. WCB TRIM-STELLITED, STEM 13% SW,800, 3000,B16.11 FLGD, 300, B16.5, RF/ 125 AARH SW,800, 3000,B16.11 FLGD, 300, B16.5, RF/ 125 AARH SW,800, 3000, B16.11 FLGD, 300, B16.5, RF/ 125 REV-0 Page 27 of 68

VLV.GATE

02.000

20.000

API-6D

VLV.GLOBE

00.500

01.500

BS-5352

VLV.GLOBE

02.000

20.000

BS-1873

VLV.CHECK VLV.CHECK

00.500 2.000

01.500 20.000

BS-5352 API -6D

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

CR. STEEL VLV.BALL 00.500 01.500 BS-5351 BODY-ASTM A 105,TRIMSEAT RPTFE BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003 ENP/ AISI 410 BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003 ENP/ AISI 410 BODY-ASTM A 105, PLUG-A 105 +0.003 ENP BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003 ENP

AARH FLGD, 300, B16.5, RF/ 125 AARH FLGD, 300, B16.5, RF/ 125 AARH BW, 300, B16.25, RF/ 125 AARH SW,800 3000, B16.11 FLGD, 300, B16.5, RF/ 125 AARH

VLV.BALL

02.000

20.000

API-6D

VLV.BALL

02.000

02.000

API-6D

VLV.PLUG VLV.PLUG

00.500 02.000

01.500 20.000

BS-5353 API-6D

Bolt Group(B1A) BOLT.STUD 00.500

26.000

B18.2

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

Gasket Group (B1A) GASKET 00.500

20.000

B16.20ANSI B 16.5 B16.20ANSIB 16.5

SP,WND, SS316+CAF

SPIRAL, 300

GASKET

26.000

20.000

SP,WND, SS316+CAF

SPIRAL, 300

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 28 of 68

ANNEXURE D

PIPING MATERIAL SPECIFICATION (D1A - CLASS 600#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 29 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

D1A, 600 # CARBON STEEL 1.5 MM NON IBR

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

SERVICE - REGASIFIED LNG (R-LNG) / Natural Gas NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. WALL THICKNESS OF LINEPIPE (MAIN PIPELINE) USED SHALL BE AS PER TABLE 1 ENCLOSED. BALL VALVE TO BE USED IN MAIN LINE SHALL HAVE BUTT WELDED ENDS. MAINLINE WELDING AND NDT REQUIREMENTS OF WELDS SHALL AS PER SPECIFICATION 0001-01-04-02-001. BARRED TEE SHALL BE WELDED TYPE FOR USE IN MAINLINE ONLY. MATERIAL SHALL BE AS PER ATTACHED TABLE-3 FOR PIPELINE SPECIALITY ITEMS. LR BEND,IJ,L/R, PIG SIG. SHALL BE FOR USE IN MAINLINE ONLY, MATERIAL AS PER TABLE-3. NDT OF WELDS EXCLUDING MAINLINE SHALL BE AS FOLLOWS: RADIOGRAPHY MPI : : ALL BUTT WELDS SOCKET WELDS 100% 100%

2.

3. 4.

5.

6. 7.

ALL OTHER REQUIREMENT SHALL BE AS PER S-05-02-012 8. 9. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 FLANGES OF SIZE 22 SHALL BE AS PER MSS-SP-44.

10. CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND FLANGES. 11. ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. 12. CORROSION ALLOWANCE OF 1.5 MM HAS BEEN CONSIDERED FOR TERMINAL PIPING AND 0.0 MM FOR MAIN PIPELINE 13. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND REFER STD. DRG.S-05-01-007

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 30 of 68

14. SPECIAL NOTES - D1A ITEM MAINTENANCE JOINTS PIPE JOINTS SIZE ALL 1.5 & BELOW 2.0 & ABOVE DRAINS ON LINES 1.5 ON LINES 2.0 VENTS ON LINES 1.5 ON LINES 2.0 TEMP. CONN PRESS. CONN 1.5 0.75 DESCRIPTION FLANGED, TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75 REFER STD.S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75. REFER STD. S-05-01-003 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 31 of 68

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40

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

BRANCH PIPE (SIZE IN INCHES)

36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

10.000

12.000

14.000

16.000

18.000

20.000

22.000

24.000

26.000

RUN PIPE (SIZES IN INCH) D1A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

28.000

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

REV-0 Page 32 of 68

30.000

0.500

0.750

BRANCH PIPE (SIZE IN INCHES)

38

38

CODE
F H P R S

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS T W I X L TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET

Item Type Pipe Group (D1A) PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE NIPPLE NIPPLE

Lower Size (Inch)

Upper Size (Inch)

Sch./ Thk

Dim. STD

Material

Description

00.500 01.000 02.000 03.000 08.000 10.000 12.000 14.000 16.000 18.000 20.000 24.000 28.00 30.00 00.500 01.000

00.750 01.500 02.000 06.000 08.000 10.000 12.000 14.000 16.000 18.000 20.000 24.000 28.00 30.00 00.750 01.500

S160 XS XS XS 14.3 12.7 14.3 14.3 17.5 19.1 20.6 19.1 22.2 2 M M

B 36.10 B 36.10 B 36.10 B 36.10 API 5L API 5L API 5L API 5L API 5L API 5L API 5L API 5L API 5L API 5L B 36.10 B 36.10

ASTM A 106 GR.B ASTM A 106 GR.B ASTM A106 GR.B (CHARPY) ASTM A106 GR.B (CHARPY) API 5L GR.B PSL2 API 5L X-52 PSL2 API 5L X-52 PSL2 API 5L X - 52 PSL2 API 5L GR.X-52 PSL2 API 5L GR.X-52 PSL2 API 5L GR.X-52 PSL2 API 5L GR.X-52 PSL2 API 5L GR.X-52 PSL2 API 5L GR.X-52 PSL2 ASTM A 106 GR.B ASTM A 106 GR.B

PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SAW BE, SAW BE, SAW BE, SAW BE, SAW BE, SAW PBE,SEAMLESS PBE, SEAMLESS

Flange Group (D1A) FLNG.SW FLNG.WN FLNG.WN FLNG.WN 00.500 02.000 10.000 28.000 01.500 8.000 24.000 30.000 M M M M B-16.5 B-16.5 B- 16.5 B-16.47-A ASTM A 105 ASTM A 105 (CHARPY) ASTM A 694 GR. F-52 (CHARPY) ASTM A 694 GR. F-52 (CHARPY) 600, RF/125AARH 600, RF/125AARH
600, RF/125AARH

600, RF/125AARH REV-0 Page 33 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

FLNG.BLIND FLNG.BLIND FLNG.BLIND FLNG.FIG8 FLNG.FIG8 SPCR &BLIND SPCR &BLIND

00.500 02.000 26.000 00.500 02.000 10.000 26.000

01.500 24.000 30.000 01.500 08.000 24.000 30.000

B-16.5 B-16.5 B16.47A B-16.48 B-16.48 B-16.48 MNFS STD

ASTM A 105 ASTM A105 (CHARPY} ASTM A105 (CHARPY} ASTM A 105 ASTM A105 (CHARPY) ASTM A105 (CHARPY) ASTM A516 GR.70 (CHARPY)

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

Fitting Group (D1A) ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 ELBOW.45 PIPE BEND T.EQUAL T.EQUAL T.EQUAL T.EQUAL T.RED T.RED T.RED T.RED REDUC.CONC REDUC.CONC REDUC.ECC REDUC.ECC 00.500 01.000 02.000 10.000 00.500 01.000 02.000 10.000 18.000 00.500 01.000 02.000 10.000 00.500 01.000 02.000 10.000 02.000 10.000 02.000 10.000 0..750 1.500 8.000 30.000 00.750 01.500 8.000 30.000 30.000 00.750 01.500 8.000 30.000 00.750 01.500 8.000 30.000 8.000 30.000 8.000 30.000 M, M M, M M,M M,M M,M M,M M M M M M M M B-16.11 B-16.11 B-16.9 MSS-SP75 B-16.11 B-16.11 B-16.9 MSS-SP75 MSS-SP75 B 16.11 B 16.11 B-16.9 MSS-SP75 B-16.11 B-16.11 B-16.9 MSS-SP75 B-16.9 MSS-SP75 B-16.9 MSS-SP75 ASTM A 105 ASTM A 105 ASTM A 234,GR. WPB (CHARPY) MSS-SP75 GR.WPHY-52 ASTM A 105 ASTM A 105 ASTM A234, GR. WPB (CHARPY) MSS-SP75 GR.WPHY-52 MSS-SP75 GR.WPHY-52 ASTM A 105 ASTM A 105 ASTM A234,GR.WPB (CHARPY) MSS-SP75 GR.WPHY-52 ASTM A 105 ASTM A 105 ASTM A234,GR. WPB(CHARPY) MSS-SP75 GR.WPHY-52 ASTM A234,GR. WPB(CHARPY) MSS-SP75 GR.WPHY-52 ASTM A234,GR. WPB(CHARPY) MSS-SP75 GR.WPHY-52 SPECIFICATION 0001-01-05-02-001 SW, 6000 SW, 3000 BW, 1.5D BW, 1.5D SW, 6000 SW, 3000 BW, 1.5D BW, 1.5D BW, 1.5D SW, 6000 SW, 3000 BW BW SW, 6000 SW, 3000 BW BW BW BW BW BW REV-0 Page 34 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SWAGE.CONC SWAGE.ECC CAP CAP CAP CAP PLUG PLUG CPLNG.FULL CPLNG.FULL CPLNG-HALF CPLNG.HALF CPLNG.LH CPLNG.LH CPLNG.RED CPLNG.RED O let group (D1A) SOCKOLET SOCKOLET WELDOLET WELDOLET

00.500 00.500 00.500 01.000 02.000 10.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000

03.000 03.000 00.750 01.500 8.000 30.000 00.750 01.500 00.750 01.500 00.750 01.500 00.750 01.500 00.750 01.500

M,M M,M

BS-3799 BS-3799 B-16.11 B-16.11

ASTM A 105 (CHARPY) ASTM A 105 (CHARPY) ASTM A 105 ASTM A 105 ASTM A234,GR. WPB (CHARPY) MSS-SP75 GR.WPHY-52 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105

PBE PBE SCRF, 6000 SCRF, 3000 BW BW SCRM, 6000 SCRM, 3000 SW, 6000 SW, 3000 SW, 6000 SW, 3000 SW, 6000 SW,3000 SW, 6000 SW, 3000

M M

B-16.9 MSS-SP75 B 16.11 B 16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11

00.500 01.000 02.000 18.000

0.750 01.500 16.000 20.000 M, XXS M, M

MSS-SP97 MSS-SP97 MSS-SP97 MSS-SP97

ASTM A 105 ASTM A 105 ASTMA 105 (CHARPY) ASTMA 694 GR. F-52 (CHARPY)

SW, 6000 SW, 3000 BW BW

Valves Group (D1A) VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR. STEEL BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL BODY-ASTMA 105,TRIM-STELLITED BODY-ASTM A 105,TRIM-SEAT RPTFE SW,800, 3000,B16.11 SW,800, 3000,B16.11 SW,800, 3000, B16.11 FLGD, 600, B16.5, RF/ 125 AARH

VLV.GLOBE VLV.CHECK VLV.BALL

00.500 00.500 00.500

01.500 01.500 01.500

BS-5352 BS-5352 BS-5351

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 35 of 68

VLV.BALL

02.000

24.000

API-6D

BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003 ENP/ AISI 410 BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003 ENP/ AISI 410 BODY-ASTM A 216 GR. WCC/ A234 GR WPC, TRIM-SEAT AISI 4140+0.003 ENP/ AISI 410 BODY-ASTM A 105, PLUG-A 105 +0.003 ENP BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003 ENP BODY-ASTM A 216 GR. WCB PLUG-A 216 GR. WCB+0.003 ENP

FLGD, 600, B16.5, RF/ 125 AARH BW, 600, B16.25, RF/ 125 AARH BW, 600, B16.25, RF/ 125 AARH SW, 800 3000, B16.11 FLGD, 600, B16.5, RF/ 125 AARH BW, 600, B-16.5, RF/ 125 AARH

VLV.BALL

26.000

30.000

API-6D

VLV.BALL

02.000

30.000

API-6D

VLV.PLUG VLV.PLUG

00.500 02.000

01.500 24.000

BS-5353 API-6D

VLV.PLUG

02.000

24.000

API-6D

Bolt Group(D1A) BOLT.STUD 00.500 30.000 B18.2 BOLT: 193 GR.B7,NUT: A194 GR. 2H

Gasket Group(D1A) GASKET 00.500 24.000 B16.20ANSI B16.5 B16.20ANSI B16.47A SP,WND, SS316+CAF SPIRAL, 600

GASKET

26.000

30.000

SP,WND, SS316+CAF

SPIRAL, 600

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 36 of 68

ANNEXURE E

PIPING MATERIAL SPECIFICATION (A4A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 37 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

A4A, 150 # CARBON STEEL 1.5 MM LOW TEMPERATURE SERVICE

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

SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY MPI 3. 4. 5. : : ALL BUTT WELDS SOCKET WELDS 100% 100%

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226 IMPACT TESTING IS REQUIRED ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

6. 7.

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

ITEM MAINTENANCE JOINTS PIPE JOINTS

SIZE ALL 1.5 & BELOW 2.0 & ABOVE

DESCRIPTION FLANGED, TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD S-05-01-003 AS PER P&ID OR 0.75 REFER STD. S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75.REFER STD. S-05-01-003 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS

ON LINES 1.5 ON LINES 2.0 ON LINES 1.5 ON LINES 2.0

TEMP. CONN PRESS. CONN

1.5 0.75

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 38 of 68

72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40

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

BRANCH PIPE (SIZE IN INCHES)

36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5

10.000

12.000

RUN PIPE (SIZES IN INCH) A4A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

14.000

0.500 0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

SPECIFICATION 0001-01-05-02-001

BRANCH PIPE (SIZE IN INCHES)

38

38

REV-0 Page 39 of 68

CODE
F H P R S Item Type

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Upper Lower Size Size (Inch) (Inch) T W I X L Sch./ Thk Dim. STD TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET Material Description

Pipe Group (A4A) PIPE PIPE PIPE PIPE NIPPLE NIPPLE 00.500 01.000 02.000 03.000 00.500 01.000 00.750 01.500 02.000 14.000 00.750 01.500 S160 XS XS STD M M B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS PBE,SEAMLESS PBE, SEAMLESS

Flange Group (A4A) FLNG. WN 00.500 FLNG.BLIND FLNG.FIG.8 SPCR &BLIND 00.500 00.500 10.000

14.000 14.000 8.000 14.000

B-16.5 B-16.5 ASMEB16.48 ASMEB16.48

ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2

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

150, FF/125 AARH

Fitting Group (A4A) ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL T.EQUAL T.RED T.RED 00.500 01.000 02.000 00.500 01.000 02.000 00.500 01.000 02.000 00.500 01.000 0.750 1.500 14.000 0.750 1.500 14.000 00.750 01.500 14.000 00.750 01.500 M M M B-16.11 B-16.11 B-16.9 B-16.11 B-16.11 B-16.9 B 16.11 B 16.11 B-16.9 B-16.11 B-16.11 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 SW, 6000 SW, 3000 BW, 1.5D SW, 6000 SW, 3000 BW, 1.5D SW, 6000 SW, 3000 BW SW, 6000 SW, 3000

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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T.RED REDUC.CONC REDUC.ECC SWAGE.CONC SWAGE.ECC CAP CAP CAP CPLNG.FULL CPLNG.FULL CPLNG-HALF CPLNG.HALF CPLNG.LH CPLNG.LH CPLNG.RED CPLNG.RED

02.000 02.000 02.000 00.500 00.500 00.500 01.000 02.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000

14.000 14.000 14.000 03.000 03.000 00.750 01.500 14.000 00.750 01.500 00.750 01.500 00.750 01.500 00.750 01.500

M, M M,M M,M M,M M,M

B-16.9 B-16.9 B-16.9 BS-3799 BS-3799 B-16.11 B-16.11

ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2

BW BW BW PBE PBE SCRF, 6000 SCRF, 3000 BW SW, 6000 SW, 3000 SW, 6000 SW, 3000 SW, 6000 SW,3000 SW, 6000 SW, 3000

B-16.9 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11

O let group(A4A) SOCKOLET 00.500 SOCKOLET WELDOLET 01.000 02.000

0.750 01.500 10.000 M, XXS

MSS-SP97 MSS-SP97 MSS-SP97

ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2

SW, 6000 SW, 3000 BW

Valves Group (A4A) VLV.GATE VLV.GLOBE VLV.CHECK 00.500 00.500 00.500 01.500 01.500 01.500 API-602 BS-5352 BS-5352 BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS-304 BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304 BODY-ASTM A 350, GR.LF2, TRIM-STELLITED SW,800, 3000,B16.11 SW,800, 3000,B16.11 SW,800, 3000, B16.11

Bolt Group (A4A) BOLT.STUD 00.500 14.000 B18.2 BOLT: A 320 GR.L7, NUT:A194 GR.4

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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Gasket Group (A4A) GASKET 00.500 14.000 B16.20ANSI B16.5 SP,WND, SS316+CAF SPIRAL, 150

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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ANNEXURE F

PIPING MATERIAL SPECIFICATION (B4A - CLASS 300#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 43 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

B4A, 300 # CARBON STEEL 1.5 MM LOW TEMPERATURE SERVICE

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

SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND UPTO -45 DEG C.HYDROCARBONS, XYLENE, PROPYLENE, LPG, METHANOL, NH3, GAS FLARE ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY MPI 3. 4. 5. : : ALL BUTT WELDS SOCKET WELDS 100% 100%

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226 IMPACT TESTING IS REQUIRED ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007

6. 7.

SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS SIZE ALL 1.5 & BELOW 2.0 & ABOVE DRAINS VENTS ON LINES 1.5 ON LINES 2.0 ON LINES 1.5 ON LINES 2.0 TEMP. CONN PRESS. CONN 1.5 0.75 DESCRIPTION FLANGED, TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75 REFER STD. S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75. S-05-01-004 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

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SPECIFICATION 0001-01-05-02-001

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

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

10.000

12.000

RUN PIPE (SIZES IN INCH) B4A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

14.000

0.500 0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

SPECIFICATION 0001-01-05-02-001

REV-0 Page 45 of 68

CODE
F H P R S Item Type

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch) T W I X L Dim. STD TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET Material Description

Pipe Group (B4A) PIPE PIPE PIPE PIPE PIPE NIPPLE NIPPLE 00.500 01.000 02.000 03.000 12.000 00.500 01.000 00.750 01.500 02.000 10.000 14.000 00.750 01.500 S160 XS XS STD S40 M M B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS PBE,SEAMLESS PBE, SEAMLESS

Flange Group (B4A) FLNG. SW FLNG. WN FLNG.BLIND FLNG.FIG.8 SPCR &BLIND 00.500 02.000 00.500 00.500 10.000 1.50 14.000 14.000 8.000 14.000 M M B-16.5 B-16.5 B-16.5 ASMEB16.48 ASMEB16.48 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2
300, RF/125 AARH 300, RF/125 AARH 300, RF/125 AARH 300, FF/125 AARH

300, FF/125 AARH

Fitting Group (B4A) ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL T.EQUAL 00.500 01.000 02.000 00.500 01.000 02.000 00.500 01.000 02.000 0.750 1.500 14.000 0.750 1.500 14.000 00.750 01.500 14.000 M M M B-16.11 B-16.11 B-16.9 B-16.11 B-16.11 B-16.9 B 16.11 B 16.11 B-16.9 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 SW, 6000 SW, 3000 BW, 1.5D SW, 6000 SW, 3000 BW, 1.5D SW, 6000 SW, 3000 BW

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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T.RED T.RED T.RED REDUC.CONC REDUC.ECC SWAGE.CONC SWAGE.ECC CAP CPLNG.FULL CPLNG.FULL CPLNG-HALF CPLNG.HALF CPLNG.LH CPLNG.LH CPLNG.RED CPLNG.RED

00.500 01.000 02.000 02.000 02.000 00.500 00.500 02.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000

00.750 01.500 14.000 14.000 14.000 03.000 03.000 14.000 00.750 01.500 00.750 01.500 00.750 01.500 00.750 01.500 M, M M,M M,M M,M M,M M

B-16.11 B-16.11 B-16.9 B-16.9 B-16.9 BS3799 BS3799 B-16.9 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11

ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2

SW, 6000 SW, 3000 BW BW BW PBE PBE BW SW, 6000 SW, 3000 SW, 6000 SW, 3000 SW, 6000 SW,3000 SW, 6000 SW, 3000

O let group (B4A) SOCKOLET SOCKOLET WELDOLET 00.500 01.000 02.000 0.750 01.500 4.000 M, XXS MSSSP97 MSSSP97 MSSSP97 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 SW, 6000 SW, 3000 BW

Valves Group (B4A) VLV.GATE 00.500 01.500 API602 API600 BS5352 BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS304 BODY-ASTM A 352 GR. LCB, TRIM-STELLITED, STEM SS304 BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304 SW,800, 3000,B-16.11

VLV.GATE

00.200

24.000

FLGD,300, B16.5, RF/125AARH SW,800, 3000,B-16.11

VLV.GLOBE

00.500

01.500

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 47 of 68

VLV.GLOBE

02.000

12.000

BS1873 BS5352 BS1868 BS5351

BODY-ASTM A 352 GR.LCB, TRIM-STELLITED, STEM SS304 BODY-ASTM A 350, GR.LF2, TRIM-STELLITED BODY-ASTM A 352, GR.LCB, TRIM-STELLITED BODY-ASTM A 352, GR.LCB/ ASTM A350, GR.LF2, TRIM-BODY SEATRPTFE

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

VLV.CHECK VLV.CHECK VLV.BALL

00.500 02.000 00.500

1.500 24.000 16.000

SW,800, 3000, B-16.11


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

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

Bolt Group (B4A) BOLT.STUD 00.500 14.000 B18.2 BOLT: A 320 GR.L7, NUT:A194 GR.4

Gasket Group (B4A) GASKET 00.500 14.000 B16.20ANSI B16.5 SP,WND, SS316+CAF SPIRAL, 300

Trap/ Strainer Group (B4A) STRNR.TEMP 01.500 14.00 GAIL STD. B:A516GR.70(NORM); INT:SS304 STRNR.TEMP 00.500 1.500 GAIL STD. B:A350GR.LF2 (NORM);INT:SS304 STRNR.TEMP 02.000 14.000 M GAIL STD. B:A420GR.WPL6; INTR:SS304 BW, T-TYPE SW, Y-TYPE, 800 CONETYPE,300,FF/125AARH

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 48 of 68

ANNEXURE G

PIPING MATERIAL SPECIFICATION (D4A - CLASS 600#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 49 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

D4A, 600 # CARBON STEEL 1.5 MM LOW TEMPERATURE SERVICE

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

SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC. NOTES 1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID. 2. NDT OF WELDS SHALL BE AS FOLLOWS: RADIOGRAPHY MPI 3. 4. 5. : : ALL BUTT WELDS SOCKET WELDS 100% 100%

PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226 IMPACT TESTING IS REQUIRED ALL BRANCH CONNECTIONS INCLUDING VENT, DRAIN, PRESSURE AND TEMPERATURE CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

6. 7.

FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC. S-05-01-007 SPECIAL NOTES ITEM MAINTENANCE JOINTS PIPE JOINTS SIZE ALL 1.5 & BELOW 2.0 & ABOVE DRAINS VENTS ON LINES 1.5 ON LINES 2.0 ON LINES 1.5 ON LINES 2.0 TEMP. CONN PRESS. CONN 1.5 0.75 DESCRIPTION FLANGED, TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75, REFER STD. S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75. REFER STD. S-05-01-004 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

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SPECIFICATION 0001-01-05-02-001

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

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

10.000

12.000

14.000

16.000

RUN PIPE (SIZES IN INCH) D4A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

18.000

0.500 0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

REV-0 Page 51 of 68

CODE
F H P R S Item Type

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch) T W I X L Dim. STD TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET Material Description

Pipe Group (D4A) PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE NIPPLE NIPPLE 00.500 01.000 02.000 03.000 4.000 06.000 08.000 10.000 12.000 14.000 16.000 18.000 00.500 01.000 00.750 01.500 02.000 3.000 4.000 06.000 8.000 10.000 12.000 14.000 16.000 18.000 00.750 01.500 S160 XS XS STD XS XS XS XS 19.0 20.6 22.2 25.4 M M B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 B 36.10 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 ASTM A 333 GR.6 PE, SEAMLESS PE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SEAMLESS BE, SAW BE, SAW PBE,SEAMLESS PBE, SEAMLESS

Flange Group (D4A) FLNG. SW FLNG. WN FLNG.BLIND FLNG.FIG.8 SPCR &BLIND 00.500 02.000 00.500 00.500 10.000 1.50 18.000 18.000 8.000 18.000 M M B-16.5 B-16.5 B-16.5 ASMEB16.48 ASMEB16.48 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2 ASTM A 350 GR. LF2
600, RF/125 AARH 600, RF/125 AARH 600, RF/125 AARH 600, FF/125 AARH

600, FF/125 AARH

Fitting Group (D4A) ELBOW.90 ELBOW.90 00.500 01.000 0.750 1.500 B-16.11 B-16.11 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 SW, 6000 SW, 3000

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SPECIFICATION 0001-01-05-02-001

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ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL T.EQUAL T.EQUAL T.RED T.RED T.RED T.RED SWAGE.CONC SWAGE.ECC CAP CAP CAP PLUG PLUG CPLNG.FULL CPLNG.FULL CPLNG-HALF CPLNG.HALF CPLNG.LH CPLNG.LH CPLNG.RED

02.000 16.000 00.500 01.000 02.000 16.000 00.500 01.000 02.000 16.000 00.500 01.000 02.000 16.000 00.500 00.500 00.500 01.000 02.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500 01.000 00.500

14.000 18.000 0.750 1.500 14.000 18.000 00.750 01.500 14.000 18.000 00.750 01.500 14.000 18.000 03.000 03.000 0.750 1.500 18.000 0.750 1.500 00.750 01.500 00.750 01.500 00.750 01.500 00.750

M M

B-16.9 B-16.9 B-16.11 B-16.11

ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6-W ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6-W ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6-W ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 420 GR.WPL6-W ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350, GR.LF2 ASTM A 350 GR.LF2 ASTM A 420 GR.WPL6 ASTM A 350, GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2

BW, 1.5D BW, 1.5D SW, 6000 SW, 3000 BW, 1.5D BW, 1.5D SW, 6000 SW, 3000 BW BW SW, 6000 SW, 3000 BW BW PBE PBE SCRF, 6000 SCRF, 3000 BW SCRM, 6000 SCRM, 3000 SW, 6000 SW, 3000 SW, 6000 SW, 3000 SW, 6000 SW,3000 SW, 6000

M M

B-16.9 B-16.9 B 16.11 B 16.11

M M

B-16.9 B-16.9 B-16.11 B-16.11

M, M M, M M,M M,M

B-16.9 B-16.9 BS3799 BS3799 B-16.11 B-16.11

B-16.9 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11 B-16.11

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SPECIFICATION 0001-01-05-02-001

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CPLNG.RED

01.000

01.500

B-16.11

ASTM A 350 GR.LF2

SW, 3000

O let group (D4A) SOCKOLET SOCKOLET WELDOLET 00.500 01.000 02.000 0.750 01.500 6.000 M, XXS MSSSP97 MSSSP97 MSSSP97 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 ASTM A 350 GR.LF2 SW, 6000 SW, 3000 BW

Valves Group (D4A) VLV.GATE 00.500 01.500 API602 BS5352 BS5352 BS5353 API-6D BODY-ASTM A 350 GR. LF2, TRIM-STELLITED, STEM SS304 BODY-ASTM A 350 GR.LF2, TRIM-STELLITED, STEM SS304 BODY-ASTM A 350, GR.LF2, TRIM-STELLITED BODY-ASTM A 350, GR.LF2, PLUG:A350 GR.LF2+0.003 ENP BODY-ASTM A 352, GR.LCB/ ASTM A350, GR.LF2, TRIM-SS 304/ SS316 SW,800, 3000,B-16.11

VLV.GLOBE

00.500

01.500

SW,800, 3000,B-16.11

VLV.CHECK VLV.PLUG

00.500 00.500

1.500 1.500

SW,800, 3000, B-16.11 SW,800, 3000, B-16.11

VLV.PLUG

02.000

18.000

BW, 600, B-16.25

Bolt Group (D4A) BOLT.STUD 00.500 18.000 B18.2 BOLT: A 320 GR.L7, NUT:A194 GR.4

Gasket Group (D4A) GASKET 00.500 18.000 B16.20ANSI B16.5 SP,WND, SS316+CAF SPIRAL, 600

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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ANNEXURE H

PIPING MATERIAL SPECIFICATION (A93A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

A93A, 150 # CARBON STEEL 1.5 MM

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

SERVICE
FIRE WATER (ABOVE GROUND / UNDER GROUND) NOTES 1. FOR T-TYPE BW STRAINERS, REFER STD. NO.S-05-01-008 & S-05-01-009 2. FORGINGS ARE ACCEPTABLE IN LIEU OF PLATE MATERIAL. 3. SIZES GIVEN IN PMS ARE NOMINAL BORE FOR O.D. OF IS 3589 PIPES REFER ANSI B36.10. 4. 5. BUTTERFLY VALVE SHALL BE LUGGED WAFER TYPE UP TO 24 AND DOUBLE FLANGED BODY FOR SIZES BEYOND 24. PIPE THICKNESS ARE JOB SPECIFIC BASED ON THE SOIL PROPERTIES OF JOB SITE AND DEPTH OF TOP OF PIPE OF 1.5M. NO LIVE LOAD HAS BEEN CONSIDERED FOR CALCULATION OF PIPE THICKNESS. LIVE LOADS WHEREVER EXPECTED SHALL BE SUITABLY TAKEN CARE OF. NDT REQUIREMENT SHALL BE SAME AS FOR CLASS A1A OF GAIL STANDARD S-05-02-012 AND TAC REQUIREMENT FOR RADIOGRAPHY SHALL ALSO BE COMPLIED WITH.

6.

SPECIAL NOTES

ITEM MAINTENANCE JOINTS PIPE JOINTS

SIZE ALL 1.5 & BELOW 2.0 & ABOVE

DESCRIPTION FLANGED, TO BE KEPT MINIMUM SW COUPLING BUTT WELDED REFER GAIL STD.S-05-01-003 AS PER P&ID OR 0.75 REFER STD. S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75REFER STD. S-05-01-003. FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S-05-01-006

DRAINS VENTS

ON LINES 1.5 ON LINES 2.0 ON LINES 1.5 ON LINES 2.0

TEMP. CONN PRESS. CONN

1.5 0.75

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 56 of 68

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

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

10.000

12.000

RUN PIPE (SIZES IN INCH) A93A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

14.000

0.500 0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

SPECIFICATION 0001-01-05-02-001

REV-0 Page 57 of 68

CODE
F H P R S Item Type

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch) T W I X L Dim. STD TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET Material Description

Pipe Group (A93A) PIPE PIPE PIPE PIPE NIPPLE 00.500 02.000 08.000 14.000 00.500 01.500 06.000 12.000 14.000 01.500 HVY HVY 6.0 8.0 HVY IS-1239-I IS-1239-I IS-3589 IS-3589 IS-1239 (BLACK) IS-1239 (BLACK) IS-3589 GR.410 IS-3589 GR.410 IS-1239 (BLACK) PE, C. WELDED BE, C. WELDED BE, WELDED BE, SEAMLESS PBE, C. WELDED

Flange Group(A93A) FLNG. SW FLNG. SO FLNG.BLIND FLNG.FIG.8 SPCR &BLIND 00.500 02.000 00.500 00.500 10.000 1.50 14.000 14.000 8.000 14.000 M B-16.5 B-16.5 B-16.5 ASMEB16.48 ASMEB16.48 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105
150, RF/125 AARH 150, RF/125 AARH 150, RF/125 AARH 150, FF/125 AARH

150, FF/125 AARH

Fitting Group(A93A) ELBOW.90 ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL 00.500 02.000 8.000 00.500 02.000 08.000 00.500 02.000 1.500 6.000 14.000 1.500 6.000 14.000 01.500 6.000 STD STD M STD M B-16.11 B-16.9 B-16.9 B-16.11 B-16.9 B-16.9 B 16.11 B 16.9 ASTM A 105 ASTM A 234 GR.WPB ASTM A 234 GR.WPB-W ASTM A 105 ASTM A 234 GR.WPB ASTM A 234 GR.WPB-W ASTM A 105 ASTM A 234 GR.WPB SW, 3000 BW, 1.5D BW, 1.5D SW, 3000 BW, 1.5D BW, 1.5D SW, 3000 BW REV-0 Page 58 of 68

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

T.EQUAL T.RED T.RED T.RED REDUC.CONC REDUC.CONC REDUC.ECC REDUC.ECC SWAGE.CONC SWAGE.ECC CAP CAP CAP CPLNG.FULL CPLNG.HALF CPLNG.LH CPLNG.RED UNION

08.000 00.500 02.000 08.000 02.000 08.000 02.000 08.000 00.500 00.500 00.500 02.000 08.000 00.500 00.500 00.500 00.500 00.500

14.000 01.500 06.000 14.000 06.000 14.000 06.000 14.000 03.000 03.000 1.500 6.000 14.000 01.500 01.500 01.500 01.500 01.500

B-16.9 B-16.11

ASTM A 234 GR.WPB-W ASTM A 105 ASTM A 234 GR.WPB ASTM A 234 GR.WPB-W ASTM A 234 GR.WPB ASTM A 234 GR.WPB-W ASTM A 234 GR.WPB ASTM A 234 GR.WPB-W ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 234 GR.WPB ASTM A 234 GR.WPB ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105 ASTM A 105

BW SW, 3000 BW BW BW BW BW BW PBE PBE SCRF, 3000 BW BW SW, 3000 SW, 3000 SW, 3000 SW, 3000 SW, 3000

STD.,STD M, M STD.,STD M, M STD.,STD M, M M,M M,M

B-16.9 B-16.9 B-16.9 B-16.9 B-16.9 B-16.9 BS-3799 BS-3799 B-16.11

STD M

B-16.9 B-16.9 B-16.11 B-16.11 B-16.11 B-16.11 BS-3799

Valves Group(A93A) VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR. STEEL BODY-ASTM A 216 GR.WCB, TRIM-13% CR. STEEL BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR. STEEL BODY-ASTM A 216 GR.WCB, TRIM-13% CR. STEEL BODY-ASTM A 105, TRIMSTELLITED,
BODY-ASTM A 216 GR. WCB, TRIM-13% CR.STEEL,

SW,800, 3000,B-16.11

VLV.GATE

02.000

24.000

API-600

FLGD, 150, B16.5, RF/125AARH SW,800, 3000,B-16.11

VLV.GLOBE

00.500

01.500

BS-5352

VLV.GLOBE

02.000

16.000

BS-1873

FLGD, 150, B16.5, RF/125AARH SW,800, 3000,B-16.11 WAFL, 150, B16.5, WAF/ 125AARH

VLV.CHECK VLV.BTRFLY

00.500 02.000

1.500 24.000

BS-5352 BS-5155

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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Bolt Group(A93A) BOLT.STUD 00.500 14.000 B18.2 BOLT: A 193 GR.B7, NUT:A194 GR.2H

Gasket Group(A93A) GASKET 00.500 14.000 B16.21ANSI B16.5 IS-2712-GR. W/3 RING, 150, 2MM

Trap/ Strainer Group(A93A) STRNR.PERM 00.500 1.500


MNFSTD

B:A105;INT;SS304

SW, Y-TYPE, 800

STRNR.PERM

02.000

6.000

GAIL STD GAIL STD

B:A234GR.WPB;INT:SS304

BW, T-TYPE

STRNR.PERM

08.000

14.000

B:A234GR.WPBW;INT:SS304

BW, T-TYPE

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 60 of 68

ANNEXURE I

PIPING MATERIAL SPECIFICATION (J2A - CLASS 150#)

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 61 of 68

PIPING CLASS BASE MATERIAL CORROSION ALLOWANCE SPECIAL REQUIREMENT

: : : :

J2A, 150 # CS (Galv.) 0 MM

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

SERVICE
POTABLE WATER (ABOVE GROUND), FIRE WATER-SPRINKLER SYSTEM AFTER ORIFICE NOTES 1. NDT REQUIREMENTS AS PER GAIL STANDARD S-05-02-012 2. THREADED JOINTS SHALL BE MADE WITH 1 WIDTH PTFE JOINTING TAPE. 3. SURFACES WHERE GALVANISING HAS BEEN BURNT OFF SHALL BE WIRE BRUSHED AND COLD GALVANISED WITH ZINC COATING COMPOUND. SPECIAL NOTES

ITEM MAINTENANCE JOINTS

SIZE 1.5 & BELOW 2 & ABOVE

DESCRIPTION UNIONS (SCRF) TO BE KEPT MINIMUM FLANGED (SCREWED) TO BE KEPT MINIMUM SCREWED COUPLING

PIPE JOINTS

UP TO 6

DRAINS VENTS

ON LINES 1.5 ON LINES 2.0 ON LINES 1.5 ON LINES 2.0

REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75 REFER STD. S-05-01-004 REFER GAIL STD. S-05-01-003 AS PER P&ID OR 0.75. REFER STD. S-05-01-004 FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005 SCREWED NIPPLE WITH VALVE TO SPEC. S-05-01-006

TEMP. CONN PRESS. CONN

1.5 0.75

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8.0 6.0 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.25 1.0 0.75 0.5 T 0.500 0.500 T T 0.750 T T T 1.000 1.250 T T T 1.500 T T T 2.000 2.500 T T T 3.000 3.500 T T T 4.000 5.000 T T T 6.000 T T T T T T T T T T T T T T T

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

RUN PIPE (SIZES IN INCH) J2A

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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CODE
F H P R S Item Type

DESCRIPTION
SADDLE FUSED JT H.COUPLING PIPE TO PIPE REINFORCED SOCKOLETS Lower Upper Sch./ Size Size Thk (Inch) (Inch) T W I X L Dim. STD TEES WELDOLETS INSTRUMENT TEE REFER NOTES SWEEPOLET Material Description

Pipe Group (J2A) PIPE 00.500 06.000 HVY IS-1239-I IS-1239 (GALV) SCRM, WELDED

Flange Group(J2A) FLNG. SCRD 00.500 FLNG.BLIND FLNG.FIG.8 00.500 00.500

06.00 06.000 06.000

B-16.5 B-16.5 ASMEB16.48

ASTM A 105 (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.)

150, FF/125 AARH 150, FF/125 AARH 150, FF/125 AARH

Fitting Group(J2A) ELBOW.90 ELBOW.90 ELBOW.45 ELBOW.45 T.EQUAL T.EQUAL T.RED T.RED SWAGE.CONC SWAGE.ECC CAP CAP CPLNG.FULL CPLNG.HALF CPLNG.LH CPLNG.RED 00.500 02.000 00.500 02.000 00.500 02.000 00.500 02.000 00.500 00.500 00.500 02.000 00.500 00.500 00.500 00.500 1.500 6.000 1.500 6.000 01.500 6.000 01.500 6.000 03.000 03.000 1.500 6.000 01.500 01.500 01.500 01.500 M,M M,M B-16.11
IS-1239-II

ASTM A 105 (GALV.) IS-1239 (PART-II) (GALV.) ASTM A 105 (GALV.) IS-1239 (PART-II) (GALV.) ASTM A 105 (GALV.) IS-1239 (PART-II) (GALV.) ASTM A 105 (GALV.) IS-1239 (PART-II) (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.) IS-1239 (PART-II) (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.) ASTM A 105 (GALV.)

SCRF, 3000 SCRF, NA SCRF, 3000 SCRF, NA SCRF, 3000 SCRF, NA SCRF, 3000 SCRF, NA TBE TBE SCRF, 3000 SCRF, NA SCRF, 3000 SCRF, 3000 SCRF, 3000 SCRF, 3000

B-16.11
IS-1239-II

B-16.11
IS-1239-II

B-16.11
IS-1239-II

BS-3799 BS-3799 B-16.11


IS-1239-II

B-16.11 B-16.11 B-16.11 B-16.11

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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UNION

00.500

06.000

IS-1239-II

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

SCRF, NA

Valves Group(J2A) VLV.GATE 00.500 01.500 IS:778 CL.2 IS:780 IS:778 CL.2 IS:778 CL.2 IS:5312 (PT-1) BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2 BODY-IS 210,GR.FG 200, TRIM-IS 320 ALLOY HT2 BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2 BODY-IS 318 GR.2 LEADED TIN BRONZE, TRIM-IS320 ALLOY HT2 BODY-IS 210 GR.FG 200, TRIM-IS 320 ALLOY HT2 SCRF, CL.2, 3000, B1.20.1 FLGD, PN 1.6, B 16.1,FF/125AARH SCRF, CL.2, 3000, B1.20.1 SCRF, CL.2, 3000, B1.20.1 FLGD, PN1.6, B-16.1, FF/125AARH

VLV.GATE VLV.GLOBE

02.000 00.500

6.000 01.500

VLV.CHECK

00.500

1.500

VLV.CHECK

02.000

6.000

Bolt Group(J2A) BOLT.M/C 00.500 6.000 B18.2 BOLT: A 307, GR.B (GALV), NUT:A563 GR.B (GALV)

Gasket Group(J2A) GASKET 00.500 6.000 B16.21ANSI B16.5 BUTYL RUBBER FULL FACE, 150, 2MM

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

REV-0 Page 65 of 68

ANNEXURE-I LIST OF ATTACHMENTS

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

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

DOCUMENT NO. S-05-01-001 S-05-01-002 S-05-01-003 S-05-01-004 S-05-01-005 S-05-01-006 S-05-01-007 S-05-01-008 S-05-01-009 S-04-02-001 S-04-02-002 S-04-02-015 S-04-02-016 S-04-02-019 S-04-02-013 S-04-02-014 S-04-02-013 S-05-02-002 S-05-02-001 S-05-02-003 S-05-02-004 S-05-02-005 S-05-02-006 S-14-06-001 S-05-02-014 S-05-02-011 S-05-02-013 S-05-02-012

REV . 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
REV-0 Page 66 of 68

GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

29 30 31 32 33 34 35

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

S-04-02-017 S-04-02-024 S-04-02-018 S-04-02-008 S-04-02-007 S-04-02-012 S-14-02-001

0 0 0 0 0 0 0

LIST OF DATASHEETS Sl. TITLE No. 1 Data Sheet for Scraper Launcher/ Receiver 2 Data Sheet for Pig Signaller 3 Data Sheet for Quick Opening End Closure 4 Data Sheet for Insulating Joints 5 Data Sheet for Flow Tee (Barred Tee) 18" X 18" , 600# 6 Data Sheet for Flow Tee (Barred Tee) 18" X 12" , 600# 7 Data Sheet for Flow Tee (Barred Tee) 18" X 8" , 600# 8 Data Sheet for Ball Valve 9 Data Sheet for Gas Powered Valve Actuator 10 Data Sheet for Plug Valve 11 Data Sheets for Gate Valves of Size below 2 DATA SHEET NO. 0001-01-04-04-PL/PR-001 0001-01-04-04-PSG-001 0001-01-04-04-QOEC-001 0001-01-04-04-IJ-001 0001-01-04-04-FLT-001 0001-01-04-04-FLT-002 0001-01-04-04-FLT-003 0001-01-05-04-BV-001 0001-01-04-04-GVA-001 0001-01-04-04-PV -001 0001-01-05-04-GV-001 RE V. 0 0 0 0 0 0 0 0 0 0 0

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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TABLE-3

PIPELINE SPECIALITY ITEMS


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

2 3

FLOW TEES (BARRED TEES)

INSULATING JOINTS

for 18 dia. pipeline for Sultanpur to Neemrana API 5L Gr. X-60 PSL2, 9.5 mm wall thickness for 12 dia. pipeline for Bhiwadi. API 5L Gr. X-60 PSL2, 7.8 mm wall thickness for 10 dia. pipeline for Gurgaon 18 X 18 X 18 - MSS-SP-75 Gr. WPHY-70 18 X 18 X 12 - MSS-SP-75 Gr. WPHY-70 18 X 18 X 8 - MSS-SP-75 Gr. WPHY-70 Monoblock type Pups / Body: 18 API 5L Gr. X 70, PSL-2 / ASTM A694 Gr. F70 (CHARPY) 12 - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 10 - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 8 - API 5L Gr. X 60, PSL-2 / ASTM A694 Gr. F60 (CHARPY) 18 Body: API 5L Gr. X-70 PSL2 Reducer: MSS-SP-75 Gr. WPHY-70 Neck: API 5L Gr. X-70 PSL2 QOEC: ASTM A 105 (CHARPY) Body: ASTM A 105 (CHARPY) Internals: SS316

SCRAPPER LAUNCHER & RECIEVER

PIG SIGNALLER

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

PIPING MATERIAL SPECIFICATION GAIL (INDIA) LTD NEW DELHI

SPECIFICATION 0001-01-05-02-001

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WELDING SPECIFICATION FOR MAIN LINE

FOR TRANSPORTATION OF GAS


SPUR LINE CHAINSA JHAJJAR PIPELINE

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 1 of 52

Copyright GAIL All rights reserved

CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 SCOPE APPLICABLE CODES AND STANDARDS BASE MATERIAL WELDING CONSUMABLES EQUIPMENT AND ACCESSORIES WELDING PROCESSES BEVEL CLEANING AND BEVEL INSPECTION ALIGNMENT AND SPACING WEATHER CONDITIONS WELDING HEAT TREATMENT INSPECTION AND TESTING REPAIR OF WELDS ANNEXURE 1 : DESTRUCTIVE TESTING ANNEXURE 2 : ULTRASONIC TESTING ANNEXURE 3 : AUTOMATED ULTRASONIC TESTING ANNEXURE 4 : RADIOGRAPHY TESTING EXHIBIT-A : ELECTRODE QUALIFICATION TEST RECORD EXHIBIT-B : STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION EXHIBIT-C : WELDING PROCEDURE QUALIFICATION TEST RECORD EXHIBIT-D : WELDER QUALIFICATION TEST RECORD EXHIBIT-E : WELDERS IDENTIFICATION CARD EXHIBIT-F : RADIOGRAPHIC PROCEDURE FOR PIPE WELDING

GAIL (INDIA) LTD NEW DELHI

WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

REV- 0 Page 2 of 52

Copyright GAIL All rights reserved

1.0

SCOPE The requirements stated herein shall be followed for the fabrication of all types of welded joints of carbon steel main pipeline system and related facilities. The welded pipe joints shall include the following: a) All line pipe joints of the longitudinal and circumferential butt-welded and socket welded types. b) Attachments of castings, forgings, flanges and other supports to pipes. c) Welded manifold headers and other sub-assemblies. d) Welded branch connections. e) Joints in welded/fabricated piping components. f) The attachments of smaller connections for vents, drain drips and other instrument tappings. Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his responsibilities and guarantees.

2.0

APPLICABLE CODE AND STANDARDS All welding work, equipment for welding, heat treatment, other auxiliary functions and the welding personnel shall meet the requirements of the latest editions of the codes, standards and specifications listed below: a) b) c) d) e) Code for Gas Transmission and Distribution Piping Systems, ANSI B31.8. Standard for Welding of Pipelines and Related Facilities, API 1104. Specification for Welding Electrodes and Filler Materials, ASME Sec. II Part C Non-Destructive Examination, ASME Sec. V. Welding and Brazing Qualifications, ASME Sec. IX

3.0

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

4.0

WELDING CONSUMABLES a) The CONTRACTOR shall provide at his own expense all the welding consumables necessary for the execution of the job such as electrode/filler wire, oxygen, acetylene etc. and these shall bear the approval of the COMPANY.
WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS SPECIFICATION 0001-01-04-02-001 REV- 0 Page 3 of 52

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b) The welding electrodes/filler wires supplied by the CONTRACTOR shall conform to the class specified in the welding specification chart attached along with other project data sheets. The materials shall be of the make approved by the COMPANY. c) The welding consumables shall suitable for the welding process recommended and the base metal used. The physical properties of the welds produced by an electrode/ filler wire recommended for the welding of a particular base metal shall not be lower than the minimum values specified for the base metal, unless otherwise specified in the welding specification chart and shall correspond to the physical properties of the class of electrode/ filler wire adopted. The choice of welding consumables shall be made after conducting the required tests on the electrode/ filler wire as per relevant standards, and shall be the sole prerogative of the COMPANY. d) The CONTRACTOR shall submit batch test certificate(s) from each electrode/ filler wire manufacturer(s) furnishing all details of physical and chemical tests carried out by them for each batch of electrodes to be used. e) Electrode/ filler metal qualification test records shall be submitted as per the attached Exhibit-A in respect of the electrodes/filler metal tested by the CONTRACTOR for obtaining the approval from the COMPANY. f) All electrodes/filler wire shall be purchased in sealed containers and stored properly to prevent deterioration. Except the cellulosic coated electrodes, the electrodes removed from the containers shall be kept in the holding ovens, at the temperature recommended by the electrode(s) manufacturer(s). Oven shall be used for the low hydrogen electrode only. Out-of-the oven time of electrodes before they are consumed shall not exceed the limits recommended by the electrode manufacturer(s). The welding consumables shall be handled with care to avoid any damage to the flux covering. Different grades of welding consumables shall be stored separately. Cellulosic electrodes shall be used as per the specific recommendation made by the manufacturer. g) The welding consumables used shall be free from rust, oil, grease, earth and other foreign matter, which affect the quality of welding. h) Shielding Gas The composition and the purity of the shielding gas required by the welding GMAW and FCAW processes shall bear the approval of the COMPANY. An appropriate gases or gas mixture of the following quality shall be used. 1. Argon gas complying with BS 4365. 2. Carbon dioxide gas complying with type 1 specified in BS 4105 3. Gas mixtures that have been proved to be satisfactory as a result of procedure approval tests.
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When a gas mixture is used, which has specified additions viz.. 2% O2, 5% CO2, the variation of such addition shall not exceed +10% of that stated. Moisture content shall correspond to a dew point of -300C or lower. 5.0 EQUIPMENT AND ACCESSORIES The CONTRACTOR shall have sufficient number of welding and cutting equipment, auxiliaries and accessories of sufficient capacities to meet the target schedules. 5.1 All the equipment for performing the preheating or heat treatment, including transformers, thermocouples, pyrometers, automatic temperature recorders with suitable calibration arrangements, etc. shall be provided by the CONTRACTOR, at his own expense and these shall bear the approval of the COMPANY. Adequate means of measuring current and voltage shall be available. Redoing of any work necessitated by the faulty equipment or due to the wrong operation carried out by the CONTRACTOR shall be done at his own expense. WELDING PROCESSES Welding of various materials under this specification shall be carried out using the following process.

5.2 6.0 6.1

6.1.1 Main Line 18 Sultanpur-Neemrana Pipeline, 12 Bhiwadi Line, 10 Manesar line & 10 Gurgaon Line Semi-automatic Flux Cored Arc Welding for fill and cap passes, with root pass welding by Surface Tension Transfer Process (STTP) or Gas Tungsten Arc Welding (GTAW) process and Manual SMAW where Semi-Automatic is not possible. 6.1.2 However semiautomatic welding processes shall be employed only with the approval of Engineer-in-Charge. Welding procedure shall be adopted and consumables used shall be specifically approved. A combination of different welding process could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Engineer-in-Charge. 6.1.3 Tie-Ins and Crossings Any of the processes specified above as per qualified procedures. 6.1.4 Double jointing of two pipe lengths using Submerged Arc Welding (SAW) process in a specially laid pipe welding yard is also permitted. Any deviation desired by the CONTRACTOR shall be obtained through the written consent of the COMPANY. 6.2 The welding procedure adopted and the consumables used shall be specifically approved.
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6.3

A combination of different welding processes or a combination of welding consumables of different classes/makes could be employed for a particular joint, only after duly qualifying the welding procedures to be adopted and obtaining the approval of the COMPANY. BEVEL CLEANING/BEVEL INSPECTION The line pipe supplied by the COMPANY shall have bevel ends as specified in the applicable specification for the line pipe attached with the Bid Package. Any modification thereto, if required by the CONTRACTOR due to the specific welding technique, shall be carried out by the CONTRACTOR at his own cost. Before welding, all the rust and foreign matter shall be removed from the bevelled-ends by power operated tools. Bevel cleaning shall be effected both inside and outside and for a minimum distance of 25 mm from the edge of the weld bevel. The bevels shall be thoroughly inspected at this stage. If any of the ends of the pipe joint is damaged to the extent that satisfactory weld spacing cannot be obtained and local repair by grinding cannot be successfully done, the damaged end shall be cut and re-bevelled with an approved bevelling machine to the satisfaction of the COMPANY. Manual cutting and weld repairs of bevels is not allowed. Should laminations, split ends or inherent manufacturing defects in the pipe be discovered, the lengths of pipe containing such defects shall be removed. For such pipes, the new bevel shall be examined 100% visually and 100% by dye-penetrant or MPI method. A report shall examined 100% visually and 100% by dye-penetrant or MPI method. A report shall be generated after carrying out the tests and submitted to the COMPANY for approval.

7.0

8.0

ALIGNMENT AND SPACING Immediately prior to line-up, the CONTRACTOR shall inspect the pipe ends both inside and outside for damages, dents, laminations etc. Pipe for welding shall be set up, correctly spaced, allowing for the temperature changes during welding. Incorrect alignment shall in no circumstances be sprung into position. Temporary attachments of any kind shall not be welded to the pipe. Welds joining the sections of the pipeline, valve installation or similar welds classified as tie-in welds shall be made in the trench. Otherwise the alignment and welding shall be made alongside the ditch with the pipe supported on skids and pack pads or other suitable means approved by COMPANY, for at least 500 mm length above the ground, unless approved otherwise by the COMPANY in specific cases. Seam orientation of welded pipes shall be selected to ensure that, at the circumferential welds, the longitudinal welds shall be staggered in the top 900 of the pipeline, or 250 mm whichever is the lesser. A longitudinal joint shall pass an appurtenance of a structural element at a minimum distance of 50 mm. Should a section of the line containing uncompleted welds fall from the skids, the CONTRACTOR shall immediately inform the COMPANY. Every effort shall be made to reduce misalignment by the use of the line-up clamp and rotation of the pipes to the best fit. For pipe of the same nominal wall thickness, the offset shall not exceed 1.6 mm. The offset may be checked from
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outside using dial gauges. Any branch connection sleeve, etc. shall be at least 150 mm from any other weld. The welds for fittings shall be so located that the toe of the weld shall not come within 50 mm of the toe of any other weld. Cold adjustment is permissible only in cases of slight misalignment and may only be carried out with a bronze headed hammer. Hot adjustment shall not be permitted. When welding pipes of different wall thickness is permitted by the COMPANY, a special transition piece shall be used. This shall have a minimum of 1:4 taper. The weld in the transition piece shall be subjected to both Ultrasonic and Radiography Testing. The root gap shall be accurately checked and shall conform to the qualified welding procedure. The use of internal line-up clamps is mandatory for pipe diameters 10 and above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe10 etc.) where it is impossible to use internal clamps, an external line-up clamp maybe used. The internal line-up clamp shall not be released before the entire first pass has been completed. When an external line-up clamp is used, all the spaces between the bars or at least 60% of the first pass shall be welded before the clamp is released and the pipe shall remain adequately supported on both sides of the joint. Segments thus welded shall be equally spaced around the circumference of the pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by grinding, so as to ensure continuity of the weld bead. 9.0 WEATHER CONDITIONS The parts being welded and the welding personnel shall be adequately protected from rain and strong winds. In the absence of such protection, no welding shall be carried out. The completed welds shall be suitably protected in case of bad weather conditions. 10.0 WELDING 10.1 Root Pass a) The root pass shall be made with the electrodes/filler wires recommended in the welding specification chart attached. The size of the electrodes used shall be as per the qualified welding procedure.

b) Position or roll welding (for yard doubler jointing) may be permitted. Separate procedures shall be submitted and qualified for up hill, down hill, vertical down and roll welding. The vertical up method of welding shall be used for the root pass of the tie-ins, special crossings, fittings and special parts, fillet welds, repairs and when an external line up clamp is used. The down hill welding may be used for the root run welding of tie-ins and special crossings when (a) the
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edges are machined or have equivalent preparation, (b) line up clamps are used and the fit up is geometrically and mechanically similar to one of the ordinary line welding without misalignment or unevenness. c) The root pass of butt joints shall be executed properly so as to achieve full penetration with complete fusion of the root edges. Weld projection inside the pipe shall not exceed 1.6 mm wherever not specified by the applicable code. d) Any deviations from the recommended welding techniques and welding consumables indicated in the welding specification chart shall be permitted only after obtaining written approval of the COMPANY. e) Welding shall be continuous and uninterrupted during a pass. f) On completion of each run, craters, welding irregularities, slag etc. shall be removed by grinding and chiseling.

g) While the welding is in progress, proper care shall be taken to avoid any kind of movement of the components, shocks, vibration and stresses to prevent occurrence of weld cracks. h) Fillet weld shall be made by Shielded Metal Arc Welding (SMAW) process, irrespective of the thickness and class of piping. SMAW electrode size shall not exceed 3.25 mm diameter for the socket joint. At least two passes shall be made on the socket weld joint. Peening shall not be used.

i) 10.2

Joint Completion The first pass shall be carried out by a minimum of two welders/welding heads, working simultaneously and so placed as to cause minimum distortion of the pipe. The number of welders/ welding heads and the allowable welding sequences shall be as those laid down in the Qualified Welding Procedure Specification (QWPS). Once the deposit of the first pass has been started, it must be completed as rapidly as possible, reducing interruptions to the minimum. The welding and wire speed shall be approximately same as that established in the QWPS. The pipe shall always be adequately supported and must not be bumped or shaken during welding. The clamp shall be removed as indicated in Clause 8.0. Before starting the second pass, the first pass shall be cleaned and flattened with rotating grinders. The interruption between the completion of the first pass and the starting of the second pass shall be as per the qualified welding procedures.

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The welding speed selected shall enable production of a bead which is sufficiently thick and with consistent fusion and without any under cutting. The time lapse between the second and the third pass shall be as stated in the procedure specification, normally not exceeding five minutes. After completion of the third or following passes, welding operations may be suspended to allow the joint to cool down, provided the thickness of the weld metal deposited is equal to at least 50% of the pipe thickness. Upon restarting, depending on the materials, wall thickness and welding process, a preheating of at least 1000C shall be applied. Subsequent passes up to weld completion shall be protected to avoid rapid cooling, if meteorological conditions so dictate. Cleaning between the passes shall be done carefully to reduce the possibility of inclusions. The weld bead starting and finishing points shall be staggered from pass to pass. Arc-strikes outside the bevel on the pipe surface are not permitted. Arc-strike or arc burn on the pipe surface outside the weld, which are caused accidentally by electrical arcs between the electrode, electrode holder, welding cable or and the pipe shall be removed by grinding in accordance with a procedure approved by the COMPANY and the repair area shall be checked by Ultrasonic or Magnetic Particle or Dye-Penetrant testing approved by the COMPANY. The pipe wall thickness after grinding shall not be less than the minimum thickness permitted for the pipe. Repair of arc strikes by welding is prohibited. The completed weld shall be carefully brushed and cleaned and shall appear free from spatters, scales, etc. The above requirements apply not only to the completed welds but also to the bare strip at least so wide as to allow full skid examination at both ends of the pipe for a good Ultrasonic inspection when it is required. 11.0 PREHEATING Preheating, if required, shall be carried out as per the following: a) Preheating requirements for the various materials shall be as per the welding specification charts. b) Preheating shall be performed using resistance or induction heating methods. Preheating by gas burners is allowed only in exceptional cases with the permission of the COMPANY. c) Preheating shall extend uniformly to at least three times the thickness of the joint, but not less than 50 mm, on both sides of the weld. d) Preheating temperature shall be maintained over the whole length of the joint during welding. Temperature indicating crayons or other temperature indicating devices shall be provided by the CONTRACTOR to check the temperature.
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12.0 12.1

INSPECTION AND TESTING General a) The Inspector authorized by the COMPANY shall have free access to all the concerned areas, where the actual work is being performed. The CONTRACTOR shall also afford the Inspector all means and facilities necessary to carry out inspection. b) The COMPANY is entitled to depute its own Inspector to the shop or field where pre-fabrication and erection of pipelines are being done, with the following objectives, but not limited to: i) ii) iii) iv) To check the conformance to relevant standards and suitability of various welding equipment and the welding performance. To supervise the welding procedure qualification. To supervise the welders performance qualification. To check whether shop/field welding being executed is in conformity with the relevant specifications and codes of practice followed in pipe construction.

c) The CONTRACTOR shall intimate sufficiently in advance the commencement of the qualification tests, welding works and acceptance tests to enable the authorized Inspector to be present to supervise them. 12.2 Welding Procedure Qualification a) Welding procedure qualification shall be carried out in accordance with the relevant requirements of API 1104 latest edition or other applicable codes and job requirements by the CONTRACTOR at his expense. The CONTRACTOR shall submit the welding procedure specifications in format as per Exhibit-C attached, immediately after the receipt of the order. b) COMPANYS Inspector will review, check and approve the welding procedure specification submitted and shall release the procedure for procedure qualification tests. The procedure qualification test shall be carried out by the CONTRACTOR under field conditions at his own expense. A complete set of the test results in format as per Exhibit-C attached shall be submitted to the COMPANYS Inspector for approval, immediately after completing the procedure qualification test and at least two (2) weeks before the commencement of actual work. Standard tests as specified in the code shall be carried out in all cases. In addition to these tests, other tests like Ultrasonic examination, Radiography, Macro/Micro examination, Hardness tests, Dye- Penetrant examination, Charpy V-notch etc. shall be carried out on the specimens following the respective qualified procedures. It shall be the responsibility of the CONTRACTOR to carry out all the tests required to the satisfaction of the COMPANYs Inspector. The destructive testing of welded joints shall be as per Annexure -1.
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12.3

Welders Qualification a) Welders shall be qualified in accordance with the API 1104 and other applicable specifications by the CONTRACTOR at his expense. It shall be the responsibility of the CONTRACTOR to carry out qualification tests of welders. The butt weld test pieces of the qualification test shall meet the nondestructive examination requirements specified in Clause 12.5 and Annexure- 2, 3, 4 (as applicable) of this specification. The COMPANYs Inspector shall witness the test and certify the qualification of each welder separately. Only those welders who have been approved by the COMPANYs Inspector shall be employed for actual welding. The CONTRACTOR shall submit the welder qualification test reports in the standard format as shown in Exhibit-D and obtain written approval, before commencement of work. b) The welders shall always have in their possession the identification card as shown in Exhibit-E and shall produce it on demand by the COMPANYs Inspector. It shall be the responsibility of the CONTRACTOR to issue the identity cards after the COMPANY has duly certified it. c) No welder shall be permitted to work without the possession of identity card. d) If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expense of the CONTRACTOR.

12.4

Visual Inspection COMPANY shall carry out inspection of all welds as per the latest editions of the applicable codes and specifications. All finished welds shall be visually inspected for parallel and axial alignment of the work, excessive reinforcement, concavity, shrinkage, cracks, under-cuts, dimensions, surface porosity and other surface defects. Undercutting adjacent to the completed weld shall not exceed the limits specified in the applicable code/standard.

12.5

Non-Destructive Examination

12.5.1 The non-destructive examination of one hundred percent (100%) girth welds shall be carried out.The non-destructive examination shall mainly consist of examination using Automated Ultrasonic Testing (AUT) as detailed in Annexure-3. This shall be applicable for all welds made by automatic GMAW process with narrow gap edge preparation and welds made by semi-automatic FCAW process. The CONTRACTOR shall make all the arrangements for the AUT of work covered by the specification at his expense. The CONTRACTOR shall furnish all the reports to the COMPANY, immediately after examination together with the corresponding interpretation reports on the approved format. The details of the AUT reports along with the joint identification number shall be duly entered in a register and signed by the
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CONTRACTOR and submitted to the COMPANY for approval. The COMPANY will review all the AUT records of welds and inform the CONTRACTOR to those welds, which are unacceptable. The decision of the COMPANY shall be final and binding in this regard. All the requirements mentioned in the specification shall be arranged and executed by the CONTRACTOR through his own resources. In addition, Radiography examination shall be required in the following cases as per Annexure-4 of this specification: a) b) c) d) On the first 100 welded joints corresponding to each automatic GMAW and semi automatic FCAW welding procedures used. When welds are repaired. When in the opinion of COMPANY, Radiography Testing is required to confirm or clarify defects indicated by Ultrasonic Testing. Welding of transition piece of pipe. In addition, Radiography inspection may be required for certain critical welds of the pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet and groove welds, other than those AUT examined, shall be subjected to Dye-Penetrant /MP testing followed by manual Ultrasonic testing. The non-destructive testing system used for inspecting welds must by approved by the COMPANY. 12.5.2 All other welds made of FCAW and SMAW processes and the Tie-in joints having API bevel shall be examined by Radiography. When Radiography is used, the provisions stated in this para shall be applicable. For all production welds, X-ray Radiography by internal crawlers be used. Welds shall meet the standards of acceptability as set forth in API 1104 and as well as the requirements laid in subsequent paragraphs. The CONTRACTOR shall make all the arrangements for the Radiography examination of work covered by the specification at his expense. The COMPANY will review all the radiographs of welds and inform the CONTRACTOR regarding unacceptable welds. The decision of the COMPANY shall be final and binding in this regard. 12.5.3 All the requirements mentioned in the specification shall be arranged and executed by the CONTRACTOR through his own resources. In addition, Ultrasonic inspection is required in the following cases as per Annexure-2 of this specification: a) b) On the first 10 welded joints corresponding to each automatic GMAW and semi-automatic FCAW welding procedures used. When welds are repaired.
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c)

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

12.5.4

Weld quality as judged on the basis of the acceptability criteria mentioned below: i) Any weld, which as a result of Radiography and/or Ultrasonic examination in the opinion of COMPANY exhibits imperfections greater than the limits stated in API 1104 latest edition or as superseded in this specification, shall be considered defective and shall so be marked with an identification point marker. In addition to the API 1104 requirements, the welds containing cracks. including crater cracks regardless of size or location are unacceptable. Suitable records shall be maintained by the CONTRACTOR on the day to day work done on welding Radiography, Ultrasonic testing. The CONTRACTOR shall present the records to the COMPANY on day-to-day basis and whenever demanded, for approval.

ii)

12.6

Destructive Testing Welds cut out for defects or for other reason may be subjected to destructive testing. The re-execution of welds shall be carried out by the CONTRACTOR at his own expense. If the results are unsatisfactory, the welding operations shall be suspended and may not be restarted, until the causes have been identified and the suitable measures that guarantee acceptable results have been adopted by the CONTRACTOR. If it is necessary in the COMPANYs opinion, the procedure shall be re-qualified. The weld joint represented by unsatisfactory welds shall stand rejected, unless investigation proves otherwise.

13.0 REPAIRS OF WELDS 13.1 With the prior permission of COMPANY welds, which do not comply with the standards of acceptability, shall be repaired or the joint cut out and re-welded. A separate welding procedure specification sheet shall be formulated and qualified by CONTRACTOR for repair welds simulating the proposed repair to be carried out. Separate procedures are required to be qualified for (a) through thickness repair (b) external repair and (c) internal repair. Welders shall be qualified in advance for repairs. The root pass, for repairs opening the root, shall be replaced by the vertical uphill technique. The procedure shall be proven by satisfactory procedure test to APIGAIL (INDIA) LTD NEW DELHI WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS SPECIFICATION 0001-01-04-02-001 REV- 0 Page 13 of 52

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1104 including the special requirements of the specification, and shall also be subjected to Metallographic examination, Hardness surveys and Charpy V-Notch testing to determine the effects of repair welding on the associated structure. Root sealing or single pass repair deposits shall not be permitted at the root. The internal root defects shall be ground out thoroughly and weld repaired with a minimum of two layers, with the last layer ground off. However, while grinding for repairs, care shall be taken to ensure that no grinding marks are left on the pipe surface anywhere. The repair shall be subjected, as a minimum requirement to the same testing and inspection requirements as the original weld. Re-Radiography of the repaired area shall be carried out. In addition, a minimum of 6 weld on either side of the repaired area shall be subjected to re-Radiography. A 100% Ultrasonic testing shall be done at the repaired area externally. Any repaired area that is wide, irregular or rough shall be rejected and a full cut out shall be done. Single pass repairs shall be subjected to 100% Dye-Penetrant/MP testing. Repairs are limited to a maximum of 30% of the weld length. Not more than two repairs are permitted on the same location. All repairs shall be carried out the day after initial Radiography or earlier. A full report of all repairs made shall be submitted every day to the COMPANY. 13.2 Weld Rejected by Accumulation of Defects Where a weld is rejected by the accumulation of defect as defined by API-1104 and this specification, repairs within these limitations are permitted. Defects in the filling and capping passes shall be repaired preferentially.

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ANNEXURE 1 (DESTRUCTIVE TESTING) 1.0 1.1 DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS PREPARATION OF SPECIMEN After satisfactory completion of all visual and non-destructive testing, the procedure test weld shall be set-aside for a period not less than 24 hours. No further work on the test weld and no cutting of test specimens from the weld shall be performed until a period of at least 24 hours has expired. Having passed the visual and the nondestructive inspection, the test weld shall be subjected to mechanical test. Weld specimens shall be taken from the positions indicated in FIG.1 & 1A of this specification from areas as free from defects as possible and for this reason it is necessary to take the previous non-destructive testing report into account. The minimum number of tests to be carried out is given in Table-1 of this specification. The test shall be carried out at laboratories approved by the COMPANY. The specimens shall be prepared in accordance with the figures given in the paragraphs that refer to the individual test. 1.2 TENSILE STRENGTH Specimens shall be taken from the position indicated in FIG.1, FIG.1A of this specification. Two (2) ISO type specimens and two (2) API type specimens shall be taken. The ISO test specimens are shown in FIG.2 of this specification. 1.2.1 Method The test shall be carried out in accordance with ISO 375.

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TABLE 1

1.3

NICK-BREAK TEST

1.3.1 Preparation Specification for Nick-Break test with notches thus worked can break in the base metal, instead of in the fusion zone. Therefore, an alternative test piece may be used after authorization by the COMPANY with a notch cut in the reinforcement of outside weld bead to a maximum depth of 1.5 mm measured from the surface of the weld bead. 1.4 MACROSCOPIC INSPECTION

1.4.1 Preparation Specimens shall be taken from the positions indicated in FIG.1 of this specification and shall be prepared in accordance with ASTM E2 and E3.The width of the macro section has to be at least three (3) times the width of the weld. The section is to be prepared by grinding and polishing and etched to clearly reveal the weld metal and heat affected zone. 1.4.2 Method Specimens shall be carefully examined under the microscope, with a magnification of at least 25 x. The COMPANY may ask for a macrograph with 5x magnification for documentation purposes. 1.4.3 Requirements
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Under macroscopic examination, the welded joints shall reveal good penetration and fusion without any defect exceeding the limits stated in the evaluation criteria of the Nick-Break test. 1.5 HARDNESS TEST

1.5.1 Preparation The prepared macro section is to be used for hardness testing using the Vickers method with 10 kg load. Indentations are to be made along traverses each approximately 1.0 mm below the surface at both side of the weld. In the weld metal, a minimum of 6 indentations equally spaced along the traverses are to be made. The HAZ indentations are to be made along the traverses for approximately 0.5 mm each into unaffected material, and starting as close to the fusion line as possible. One indentation at each side of the weld along each traverse has to be made on parent adjacent region as well as on the opposite side of the macro section along the specified traverses. 1.5.2 Method The test shall be carried out in accordance with recommendation ISO R81, Vickers hardness, using a laboratory type machine controlled as pre-recommendation ISO R146 and using a diamond pyramid penetrator set at 2.37 rad (136") with a load of 10 kg. 1.5.3 Requirements Hardness value shall not exceed the limit specified in welding specification chart. In case of a single reading strictly (+10HV) higher than the specified limit, further indentations shall be made to check if the high value was an isolated case. All the measured hardness values of the heat-affected zone shall not exceed 100 HV with respect to the average hardness value of the base metal. If the additional tests give hardness value within the specification limit, the slightly higher value may be accepted. 1.6 1.6.1 CHARPY V-NOTCH IMPACT TESTING Specimens shall be taken from the position indicated in FIG.1 of this specification. The test specimens will be prepared in accordance with ISO R 148. Charpy VNotch specimens shall have dimensions as given in Fig.3 of the specification. Three (3) test specimens shall be taken from each sample and they shall be cut and worked so that their length is transversal and perpendicular to the weld bead with the notch position as shown in FIG.4 of this specification. The notch shall be perpendicular to the roller surface. The test specimen width shall depend upon the pipe wall nominal thickness as per the following table:
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1.6.2 Test Method The test shall be carried out as indicated in ISO R148 Beam Impact Test V-Notch. Test pieces shall be immersed in a thermostatic bath and maintained at the test temperature for at least 15 minutes. They shall then be placed in the testing machine and broken within 5 seconds of their removal from the bath. The test temperature shall be as mentioned in welding specification chart. 1.6.3 Requirements The impact energy values shall be as follows:

Note 1:

These values are specified for resistance to brittle fracture only. Where additional requirements are specified in project data sheet, as for example, pipeline material with arrest properties i.e. a higher upper shelf Charpy V Notch energy for resistance against propagating ductile fractures, the same shall be followed. Only one value is permitted to be lower than average value up to the value specified.

Note 2: 1.7

BEND TEST REQUIREMENTS The Bend test specimens shall be made and tested as per the requirements of API 1104, Nineteenth Edition, September 1999. The dimensions of the Jig for guided bend test in Figure.9 of API 1104 shall be modified as specified below: Radius of the Plunger `A' = 2t
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Radius of the die. `B' = 3t + 1.6 mm Width of the die. `C' = 50.8 Where t = thickness of the specimen The acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API 1104 Nineteenth edition, September 1999.

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ANNEXURE 2 (ULTRASONIC TESTING) 1.0 ULTRASONIC TESTING In addition to the Radiography testing, Ultrasonic testing is required as per conditions listed in paragraph 12.5 of this specification. This section concerns manual Ultrasonic inspection. However Ultrasonic inspection by automatic equipment may be used if approved by the COMPANY. 1.1 GENERAL: The CONTRACTOR who carries out the Ultrasonic inspections shall have sufficient no. of qualified personnel, equipment and instruments at his disposal to be carried out the tests without hindering or delaying the pipeline assembly operations. The CONTRACTOR appointed shall supply all the requisite instruments to carry out Ultrasonic inspection at site. 1.2 SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE The CONTRACTOR shall present a Specification describing the proposed Ultrasonic testing procedure qualification. This specification shall state the following information including all the parameters described in API 1104: a) b) c) d) e) f) g) h) I) 1.3 Type of Ultrasonic testing equipment to be used Type and dimensions of transducers Frequency range Details for calibration Coupling medium Inspection technique Reference to the welding procedure where it is intended to adopt the specification Temperature range of the joints to be inspected Record details.

QUALIFICATION OF ULTRASONIC TESTING PROCEDURE


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Before the actual inspection begins, the COMPANY may require the qualification test of the Ultrasonic testing procedure. The qualification test shall be conducted under normal operating conditions on some weld made by the CONTRACTOR according to the same production procedure, where there are typical defects are intended to be detected. The qualification test shall be conducted in the presence of the COMPANYs representative. The Ultrasonic inspection procedure shall be approved by the COMPANY. 1.4 TEST PROCEDURE Circumferential welds shall be inspected from both sides using angle probes. The surface with which the probe comes into contact shall be free of metal spatter,dirt, iron oxide, and scales of any type. Therefore, it shall be necessary to clean a strip at least 50 mm wide on both sides of the weld with steel-wire brushes. The cleaned strip must be at least wide enough to allow one and a half skip examination. If echoes of doubtful origin appear during the test, it shall be necessary to inspect a convenient area on the pipe surface close to the weld, with a straight beam transducer in order to check whether any manufacturing defects are interfering with the ultrasonic beam. The equipment shall include but not be limited to the following: a) b) c) d) Ultrasonic equipment and coupling medium Sample sections for calibration of instruments Equipment for cleaning of surface to be examined Rules calibrated in centimeters for exact location of the position of defects.

The characteristics of the above listed instruments and equipment shall guarantee: a) b) The required standards of the inspection procedure previously established and approved by the COMPANY are satisfied Continuous operation.

All the instruments and equipment shall be approved by the COMPANY before being used. The COMPANY has the authority to reject any item that is considered unsuitable. The decision of the COMPANY is final. The CONTRACTOR appointed to carry out Ultrasonic inspections shall also ensure the operational efficiency and maintenance of the instruments and equipment, and shall immediately substitute any item rejected by the COMPANY.

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All the instruments and equipment necessary for carrying out Ultrasonic inspection on site shall satisfy the requirements laid down by the public boards of institutions that regulate `safety at work'. 1.5 ULTRASONIC INSTRUMENTS The Ultrasonic instruments shall have the following: a) Pulse-echo type; able to generate, receive and display on the screen of a Cathode Ray Tube (CRT); pulse at frequencies between 1 and 6 MHz. The useful part of the CRT screen shall be at least 70mm wide and at least 50mm high. Variable amplification, with steps of 1 or 2 dB over a range of a least 60 dB. The regulation control shall be accurate to within 1 dB and this accuracy shall be certified by the instrument manufacturer. May be powered by a battery or an electric generator. In the first case, the autonomy of operation (endurance) of the instrument shall be sufficient to carry out work without frequent interruptions, and the instrument shall be equipped with an automatic switch, which switches if off when the battery runs down. In the second case, there must be a voltage stabilizing device with a tolerance of 2 volts.

b) c)

1.6

PROBES The probes used shall have dimensions, frequencies, and a refraction angle suited to the type of steel, the diameter, and the thickness of the pipeline and to the joint design. REFERENCE SAMPLE PIECES The efficiency of the equipment, the effective refraction angle of the probe, and the beam output point shall be checked using a V1 and V2 sample block, IIW type or the calibration block ASTM E-428. For manual Ultrasonic testing and automated Ultrasonic testing, the reference sample pieces shall be as described in API 1104, Nineteenth Edition, para 11.4.5.

1.6

1.7

CALIBRATION The calibration, qualification of the testing procedure shall be done as provided in API 1104.

1.9

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

1.10 QUALIFICATION OF ULTRASONIC TESTING OPERATORS


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Before the actual inspection begins, the COMPANY may require a qualification test for the ultrasonic equipment operators. The operators shall be fully qualified as per a recognized standard (ASME Sec V or equivalent) and they shall have as minimum level II as described in para 11.4.3, API 1104, Nineteenth Edition. The operators shall be able to: a) b) c) d) e) Calibrate the equipment Perform an operational test under production conditions Interpret the screen picture Evaluate the size and location of reflectors Interpret the type of defects detected.

The COMPANY has the option of checking the ability of personnel employed for Ultrasonic testing by means of qualification tests. 1.11 EVALUATION OF INDICATIONS GIVEN BY ULTRASONIC TESTING Each time that echoes from the instrument amplification shall amplifications and the probe obtained, paying attention all the weld bead appear during production testing, the be altered to coincide with the reference shall be moved until maximum response is time to the probe-tube coupling.

If, under these conditions, the height of the defect echo is equal to or greater than that of the reference echo, the defect shall be evaluated according to clause 12.5 of this specification. If the defect has also been detected by the Radiography and/or Visual examination, the dimensions shall be judged according to the type of examination that detects the greater defect. Returns that are less than 50% of the reference echo will not be considered. If returns are above 50% but lower than 100% of the reference echo, and if the operator has good reasons to suspect that the returns are caused by unfavorably oriented cracks, he shall inform the COMPANY. Moreover, when there is a defect to be repaired, such defect shall be removed for a length corresponding to the one where no more return echo is given. 1.12 OTHER EQUIPMENT The use of rules calibrated in centimeters, attached to the probe is recommended for the precise location of the position of welding defects. Defect location is effected by measuring the projection distance between the probe output and the reflecting surface.
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The operators carrying out the tests may require other equipment besides the probing instrument, tools for cleaning the pipe surface viz. files, brushes etc., and coupling liquid or paste appropriate for the temperature of the section to b examined.

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ANNEXURE 3 AUTOMATED ULTRASONIC TESTING (AUT) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 INTRODUCTION REFERENCE DOCUMENTS APPROVED AGENCIES AUT SYSTEM COUPLING SEARCH UNITS CALIBRATIONS PROCEDURE TRAINING AND QUALIFICATION FIELD EXAMINATIONS AND REPORTING INTERPRETATION OF RESULTS ACCEPTANCE CRITERIA

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1.0

INTRODUCTION The specification shall be applicable for Automated Ultrasonic Testing (AUT) system suitable for pipeline girth welds. The system shall be based on focused pulse-echo, tandem or through transmission methods enhanced with mapping image and augmented by Time Of Flight Diffraction (TOFD) technique.

2.0

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

3.0

APPROVED AGENCIES Automated Ultrasonic Testing (AUT) systems and agencies who have proven track record and have done a single project of diameter 20 or above and minimum length of 50 km and also have inspected a cumulative length of 500 km or above on large diameter Pipe lines in the last ten years shall be accepted. The agency should have been approved by the reputed inspection agencies. The track record shall be submitted to the COMPANY for approval prior to engagement.

4.0

AUT SYSTEM The system shall meet and exceed the requirements of ASTM E1961-98. The system shall provide an adequate number of examination channels to ensure the complete volumetric examination of the weld through the thickness in one circumferential scan. The evaluation zones should be of maximum 2.0mm height. The instrument linearity should be such that the accuracy is within 5%. Each examination channel should be selective for pulse-echo or through transmission mode gate position and length for a minimum of two gates and gain. TOFD techniques & B-scan mapping should be available to improve characterization. Recording thresholds should be selectable to display signals between 0 and 100% of full screen height for simple amplitude and transit time recording and it should be from 0 to 100% for B-scan or mapping type recording of data. Two recordable signals output per gate should be available being either analog or digital and representative of signal height and time of flight. Measuring distance accuracy of circumferential weld shall be within 1.0 cm from zero (0) position.
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Electronic noise shall be lower than acoustical noise in all channels for the probes and sensitivities to be used during inspection. The signal to noise ratio for each channel during examination shall be at least 20 dB for shear waved probes. 5.0 COUPLING The coupling shall be obtained by using a medium suitable for the purpose. It shall be suitable for the temperature used. No residue shall remain on the pipe surface. A method should be employed to determine that constant coupling is achieved during examination. An examination of the test piece with its surface wiped dry should produce a record showing an absence of the couplant recording signal. 6.0 SEARCH UNITS The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961- 98. 7.0 CALIBRATIONS Reference standards shall be manufactured from a section of unflawed project specific line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the reference standard design to the COMPANY before manufacturing. No design changes in the reference standard shall be made without the prior approval. Annexure A3 of the standard ASTM E1961-98 provides an example for minimum requirements for reference standards. The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E 1961-98. Static and Dynamic calibration shall be done and the approved procedure shall clearly state the gain setting fixed for each channel. The reference standard should be used to verify the scanning sensitivity at the start of each shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds. A re-calibration shall be carried out if: a) b) The calibration of an inspection function differs more than +/- 3dB from the previous calibration The gate settings need to be adjusted with more than +/- 1.5 mm with the previous calibration i) after a weld repair, ii) after equipment breakdown.

In case the calibration differs from the initial setting, outside the given tolerances, the applicable probe(s) coupling shall be checked. If the calibration has to be changed, the welds before this calibration up to the previous calibration will be reexamined.
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The reference standard design for calibration shall be approved separately. The procedure for calibration and verification shall be same as given above. 8.0 PROCEDURE A detailed AUT procedure shall be prepared and qualified for each wall thickness and joint geometry to be examined prior to the start of any NDT work. Repair procedure shall be separately qualified for each joint geometry. All the requirements of ASTM E1961-98 should be met. The procedure as a minimum shall include the following: - Functional description of equipment - Reference standards and guidelines controlling equipment maintenance - Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics, Hard & Software for recording processing, Display presentation and storage of inspection data - Transducer configuration(s), characteristics types coverage. - Number of examination zones for each wall thickness to be examined. - Gate settings - Equipment settings - Description of calibration blocks including type, size and location of calibration reflectors, a) calibration intervals, b) calibration records - Static and dynamic calibration procedure - Identification of inspection starting point scanning direction and indication of length inspected - Method for scanner alignment and maintenance of alignment - Allowed temperature range - Couplant coupling and coupling control and channels provided to indicate lack of coupling and method to ensure constant coupling - Transducer and over all functional checks - Height and length sizing methodology - Surface condition and preparation - Description of inspection work - Acceptance criteria and instructions for reporting including example of recorder chart and form to be used. - A table indicating corresponding channel no., probe, type, location of reflector, probe coupling etc. 8.1 Setting of Inspection Gates

8.1.1 Pulse-echo and Tandem Channels With each transducer positioned for the peak signal response from the calibration reflector the detection gates are to be set. The gate shall start 2-6mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate ends shall be after the theoretical weld centerline. All gates will be programmed to record amplitude and/or transit distance information.
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The length of the transit distance in the root channel will be extended root penetration registration.

to

enable

8.1.2 Mapping Channels 8.1.3 The mapping gates in the body of the weld shall start 2-6mm (allowance for width of heat affected zone) before the theoretical weld bevel preparation. The gate length will be extended to enable cap reinforcement registration. The mapping gates in the root will be set identical to the pulse-echo transit distance channels to enable the registration of the root penetration. 8.1.4 TOFD Channel The TOFD gate start will be set 1 Sec before the arrival of the lateral wave and should extend up to the first back wall echo to achieve full cover of wall thickness. Note: The gate settings may be altered if geometry indications dictate. 8.1.5 Sensitivity Settings With each transducer positioned for the peak signal response from the calibration reflector (flat bottom holes), the detection gates are to be set. In this position, the probe holder is fixed to the probe frame. The equipment sensitivity (echo amplitude) for all inspection channels shall be set at 80% Full Screen Height (FSH). Mapping channels in the body of the weld will be used to detect the presence of porosity and in addition to identify the position of the weld cap reinforcement for pattern recognition purpose. The sensitivity as a minimum is equal to the related pulse- echo channels, increased with additional gain to ensure proper detection. Mapping channels in the root will be used to identify the position of the root penetration for pattern recognition purpose. The sensitivity as a minimum shall be equal to the related pulse-echo channels, increased with additional gain to ensure proper detection. he lateral wave of the TOFD channel sensitivity is set at 80% FSH. 9.0 1. TRAINING AND QUALIFICATION All Inspectors of the COMPANY (Owner) shall be imparted training at the CONTRACTORs cost. The inspector shall be provided complete awareness and knowledge regarding the equipment, limitations, capabilities complete range, method of operation, calibration, scanning, including development of suitable procedure, training on variables effecting the system performance and interpretation of results. The Ultrasonic lead operator performing the examination shall be qualified in accordance with the COMPANYs written practice and in accordance with ASNT Practice SNT-TC-1A and EN 473 Level II. He should have experience in multichannel UT equipment and be trained in using mechanized UT manipulators.
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2.

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10.0

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

11.0 INTERPRETATION OF RESULTS 11.1 General With the transit distance measurements and with the information from the mapping and TOFD channels visible on the result presentation, indications shall be judged whether they are from the weld geometry or from the defects. The coupling channels will check for coupling loss; in case of coupling loss, a re-scan shall be carried out. 11.2 Inspection Result The inspection result should be evaluated and/or reported as follows: Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below. This shall be performed in parallel and rejection against either of these criteria shall be cause for rejection of the weld. The exceptions to this are described in the following notes: 1. 2. All indications in the pulse echo channels should be evaluated which exceed the threshold level of 20% FSH. Defect length shall be measured for the pulse-echo channels from the point where the signal exceeds 20% FSH to the point the signal falls below. The largest height assessed with TOFD or the greatest measured amplitude with pulse-echo shall be assumed to apply over the whole defect length. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw diffraction tips cannot be separately distinguished, no measurement can be made to determine the defect height. In this case, the signal from the pulse echo channels will be solely used to determine that particular area of the scan. Defects shall be assessed for interaction as follows: a) Horizontal interaction If the distance between two adjacent defects is less than the length of the smaller of the two defects, then the defect shall be treated as a single defect. b) Vertical interaction Vertical interaction of defects shall be assessed using TOFD. If the distance between the two adjacent defects is less then the height of the shorter of the two defects, than the defect shall be treated as a single defect. Where the individual defects cannot be resolved by TOFD for the vertical interaction, then the defects are assumed to interact and shall be treated as a single defect.
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3.

4.

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5.

The maximum allowable accumulated defect length shall be as per the criteria given in welding specification para 12.5.1.

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

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1.0

SCOPE

ANNEXURE-4 (RADIOGRAPHY TESTING)

This annexure covers the Radiography Testing of all types of welded joints of the main pipeline. The welded joints shall include the following: i) Full girth welds on the mainline construction including double jointing of pipe, if adopted. ii) Welds for installation of block valves, insulating joints and other appurtenances and tie-ins. iii) Welds at scraper launching and receiving barrels. iv) Terminal Piping. 2.0 APPLICABLE STANDARDS This specification shall apply in conjunction with the following (all latest editions): i) API 1104, Standard for welding Pipelines and Related Facilities ii) ANSI B 31.8, Code for Gas Transmission and Distribution Piping Systems. iii) ANSI B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols. iv) ASTM E 94, Recommended practice for Radiographic Testing v) ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing v) The American Society for Nondestructive Testing. Recommended Practice No. SNT-TC 1A Supplement A. PROCEDURE The Radiography examination procedure to be adopted shall be submitted by the CONTRACTOR as per Exhibit - F. The procedure of Radiography examination shall be qualified to the entire satisfaction of COMPANY prior to use. It shall include but not be limited to the following requirements: i) iii) iv) Lead foil intensifying screens, at the rear of the film shall be used for all exposures. Type 2 and 3 films as per ASTM E-94 shall be used. A densitometer shall be used to determine film density. The transmitted film density shall be between 2.0 and 3.5 throughout the weld. The unexposed base density of the film shall not exceed 0.30. Radiography identification system and documentation for Radiography interpretation reports and their recording system.

3.0 3.1 3.2

v)

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3.3 3.4

The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior to use. The procedure of Radiography examination shall produce radiographs of sufficient density, clarity and contrast so that defects in the weld or in the pipe adjacent to the weld are clearly discernible. All the girth welds of mainline shall be subjected to 100% Radiography examination. The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after processing them, together with the corresponding interpretation reports on approved format. The details of the radiographs along with the joint identification number shall be duly entered in a register and signed by the CONTRACTOR and submitted to the COMPANY for approval. When the radiation source and the film are both on the outside of the weld and located diametrically opposite each other, the maximum acceptable length of film for each exposure shall not exceed the values given. The minimum film overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch and smaller provided that the source of film distance used is a minimum of 12 inch. Three (3) copies of each acceptable Radiography procedure (as per Exhibit-F) and three (3) copies of Radiography qualification records, shall be supplied to COMPANY. One set of the qualifying radiographs on the job shall be kept by the CONTRACTOR's authorized representative to be used as a standard for the quality of production Radiography during the job. The other two sets shall be retained by COMPANY for its permanent record. Three (3) copies of the exposure charts relating to material thickness, kilo voltage, source to film distance and exposure time shall also be made available to COMPANY by the CONTRACTOR. The CONTRACTOR shall record for each radiograph on a daily basis (1) radiograph's number, (2) approximate chainage of weld location, (3) whether or not the welds meet the specified acceptance standards, and (4) the nature and approximate location of unacceptable defects observed to correlate to a particular butt weld and welder on piping drawing and pipeline alignment drawing. Each day's production of processed radiographs shall be properly packaged separately, identified by (1) date, (2) radiography unit, (3) job locations, (4) starting and ending progress survey stations, and (5) shall include original and three (3) copies of the daily radiography record. The package shall be submitted to the COMPANY daily when possible, but in no event later than noon of the following day. The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room with controlled temperature, film viewer etc. to enable the COMPANY to examine the radiographs.
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3.5

3.6

3.7

3.8

3.9

3.10

3.11

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3.12

The CONTRACTOR, if found necessary, may modify the procedure of Radiography examination suiting to the local conditions prevailing. This shall be subjected to the approval of the COMPANY. COMPANY shall have free access to all the CONTRACTOR's work facilities in the field. Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his responsibilities and guarantees. RADIATION SOURCE Radiography examination shall be carried out using X-radiations. Radiography examination by Gamma rays using slow speed films may be allowed, at the discretion of the COMPANY in case of inaccessible joints. Radiography by Gamma ray for tie-in-joints shall be acceptable provided D4 AGFA film or equivalent is used and the required sensitivity obtained. Whenever possible, pipeline welds will be inspected by placing the radiation source inside the pipe, on the pipeline axis, with a radiation of 6.28 red. (360) If it is impossible to place the radiation source inside the pipe, the weld will be inspected with the source on the outside. An overlap of at least 40 mm at the ends of each film shall be required to ensure that the first and last location increment numbers are common to successive films and to establish that no part of a weld has been omitted. LEVEL OF QUALITY The quality level of Radiography sensitivity required for Radiography inspection shall be at least equivalent to the values in FIG.5.

3.13 3.14 4.0 4.1

4.2

5.0

6.0 6.1

PENETRAMETERS The Image Quality Indicator (IQI) shall be used for the qualification of the welding procedure and during normal line production. Radiography sensitivity shall be measured with the wire image quality indicator (Penetrameter). The Penetrameter shall be selected according to DIN-54109 or ISO-1027. For radiographs made with the source on the outside, a Penetrameter shall be placed on each side of the film with the smaller wire of the Penetrameter turned towards the end of the film itself. When a complete weld is radiographed in a single exposure using a source inside the piping, four pentrameters approximately equally spaced around the circumference shall be used. During the procedure qualification, IQI shall be placed both on the source side and on the film side. The sensitivity obtained with IQI on the source side shall not be less than the values shown in FIG.5 of this specification. The sensitivity limit may be considered to have been reached when
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the outline of the IQI, its identification number and the wire of the required diameter show up clearly on the radiograph. The COMPANY may authorize use of types of IQI other than those planned, provided that they conform to recognized standards and only if the CONTRACTOR is able to demonstrate that the minimum sensitivity level required is obtained. For this demonstration, a test shall be carried out comparing the IQI specified. The CONTRACTOR shall show up the identification number and other details of the proposed IQI, which must be visible in the test radiograph. 2.0 FILM IDENTIFICATION MARKERS All films shall be clearly identified by lead numbers, letters, and/or markers. The image of the markers shall appear on the films, without interfering with the interpretation. These markers positions shall also be marked on the part to be radiographed and shall be maintained during Radiography. 8.0 8.1 8.2 PROTECTION AND CARE OF FILM All unexposed films shall be protected and stored properly as per the requirements of API 1104 standard and ASTM E.94. The exposed and unexposed film shall be protected from heat, light, dust and moisture. Sufficient shielding shall be supplied to prevent exposure of film from radiation prior to the use of the film for Radiography exposure. RE-RADIOGRAPHY The weld joints shall be re-radiographed in case of unsatisfactory quality of the radiographs, at the expense of the CONTRACTOR. All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY in the same manner as that followed for the original welds. In addition, the repaired weld areas shall be identified with the original identification number plus the letter R to indicate the repair. When evaluating repair film, radiographers shall compare each section (exposure) of the weld with the original film to assure repair is correctly being done and original defects are removed. Prior to any repair of welds, the COMPANY will review all the radiographs of welds that contain unacceptable defects. The final disposition of all unacceptable welds shall be decided by the COMPANY.

9.0 9.1 9.2

9.3 9.4

10.0 QUALIFICATION OF RADIOGRAPHERS

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10.1 10.2

Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and to the full satisfaction of COMPANY. Certification of all the radiographers qualified as per 10.1 above shall be furnished by the CONTRACTOR to the COMPANY, before a radiographer will be permitted to perform production Radiography. The certificate record shall include: i) Background and Experience Record ii) Training Course Record iii) Technical Examination Record iv) Doctor's report on radiographer's Jacque 0-1 acquity eye test v) Date of qualification

10.3

The radiographers shall be required to qualify with each Radiography procedure they use, prior to performing the work assigned to him in accordance with the specification. PRESERVATION OF RADIOGRAPHS The radiographs shall be processed to allow storage of films without any discoloration for at least three (3) years. All the radiographs shall be presented in suitable folders for preservation along with necessary documentation. All radiographs shall become property of the COMPANY.

11.0 11.1

11.2

12.0 EQUIPMENT AND ACCESSORIES 12.1 CONTRACTOR shall make necessary arrangements at his own expense, for providing the radiographic equipment, radiographic films and all the accessories for carrying out the Radiography examination for satisfactory and timely completion of the job. For carrying out the mainline Radiography examination, the CONTRACTOR shall be equipped with suitable mobile/stationary type dark rooms. These shall have all the required facilities for film processing. Film viewer used shall be equipped with the film illuminator that has a light source of sufficient intensity and suitably controlled to allow viewing film densities up to 4.0 without damaging the film.

12.2

13.0 RADIATION PROTECTION 13.1 13.2 13.3 CONTRACTOR shall be responsible for the protection and personnel monitoring of every man with or near radiation sources. The protection and monitoring shall comply with local regulations. In view of visual hazards in the handling of Radioactive source of material, CONTRACTOR shall be solely responsible for complying with all rules and regulations set forth by Atomic Energy Commission or any other Government
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agencies of India in this regard and COMPANY shall not be responsible and shall be kept indemnified by the CONTRACTOR for default (s) of whatever nature by the CONTRACTOR. Safety equipment as considered adequate by the COMPANY for all necessary personnel shall be made available for use and maintained for immediate and proper use by the CONTRACTOR. 14.0 14.1 DISPLAY OF SAFETY INSTRUCTIONS The safety provisions shall be brought to the notice of all concerned by display on a notice board at prominent place at the work spot. The person responsible for the Safety shall be named by the CONTRACTOR.

15.0 ENFORCEMENT OF SAFETY REGULATIONS 15.1 To ensure effective enforcement of the rules and regulations relating to safety precautions, the arrangement made by the CONTRACTOR shall be open to inspection by COMPANY or its representatives.

16.0 FIRST AID AND INDUSTRIAL INJURIES 16.1 16.2 CONTRACTOR shall maintain first aid facilities for its employees and those of subcontractors. CONTRACTOR shall make outside arrangements for ambulance service and for treatment of industrial injuries. Names of those providing these services shall be furnished to COMPANY, prior to start of work and their telephone nos. shall be posted prominently in CONTRACTOR'S field office. All critical industrial injuries shall be reported promptly to the COMPANY and a copy of CONTRACTOR's report covering each personal injury requiring the attention of physician shall be furnished to the COMPANY.

16.3

17.0 NO EXEMPTION Notwithstanding the above there is nothing in these to exempt the CONTRACTORN from the operation of any other act or rules in force.

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SPECIFICATION 0001-01-04-02-001

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Sheet 1 of 3 EXHIBIT- A A: Tested at (Site name) Date: Manufacturers Name Brand Name Batch Number & Size tested Classification & Code Intended for welding in position : In combination with (if any) Code of Reference (used for testing) Special Requirements (if any) All-weld Tensile Test Base Material used Pre-heat temperature Post weld heat treatment details Visual examination Radiographic examination results Tensile test results (ELECTRODE QUALIFICATION TEST RECORD)

: : : : : : :

: : : : : :

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WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

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EXHIBIT A (CONTD.) Sheet 2 of 3 C. Impact Test Results Test Temperature : Type of Specimens (Charpy) : Notch in : Size of Specimens :

D.

Chemical Analysis Results Electrode Size Result : Batch No. :

E.

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

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WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

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EXHIBIT A (CONTD.) Sheet 3 of 3 Macro Test Results Fracture Test Results Remarks F. 1. Other Test Results Transverse tensile test : In combination with Base material used Position of welding Preheat temperature Post weld heat treatment Radiography : : : : : : : : : :

Identification No. U.T.S. Fracture in Remarks 2. Guided Bend Test :

G. Any other tests :

H. Conclusions :

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

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

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

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WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

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Sheet 1 of 1 EXHIBIT - B (STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION) Name of the Heat-Treater : Name of the Project : Specification Reference No. : 1. General Detail : 2. Furnace Details : Name of the Equipment : Type of Heating : Gas/Oil/Elect. Name of the Assembly/Part : Res./Induction Type of Heating : Drawing No : Capacity (Size) : Material : Maximum Temp.( C) : Method of temp. Measurement : Atmosphere Control : 3. Heat Treatment Cycle Details : Charging Temp. (C) : Rate of heating, (C)/Hr : Soaking Temp. (C) : Soaking Time, (Hrs.) : Rate of Cooling, (C)/Hr : Mode of Cooling : 4. Other Details, if any : Notes : The following documents shall be furnished along with the specifications: i) Material test certificates

ii) Assembly/Part Drawing

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

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

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

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WELDING SPECIFICATION FOR MAIN LINE FOR TRANSPORTATION OF GAS

SPECIFICATION 0001-01-04-02-001

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

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GAIL (INDIA) LTD NEW DELHI

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

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

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JOB SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPUR LINES OF CHAINSA-JHAJJAR PIPELINE

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SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

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TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 9.0

SCOPE DESIGN MATERIAL DELIVERY, STORAGE, HANDLING MARKING OTHER TECHNICAL REQUIREMENTS INSTALLATION DOCUMENTATION

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SPECIFICATION FOR GEOTEXTILE BAGS FOR ANTI-BUOYANCY

SPECIFICATION 0001-01-04-02-002

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

2.0 DESIGN
2.1 Geo-textile bags shall be suitable for filling with Gravel/stone ballast materials for 18 12 & 10 three layer polyethylene coated pipeline carrying liquid hydrocarbon for anti buoyancy measures in place of concrete coating. Composition and the details of materials shall be as per recommendation of anufacturer The geo-textile bags shall meet the following requirements: a. Body fabric material must be rated for geo-textile use and as such must be woven with minimum permeability rating to suit specified Gravel/stone ballast materials. Geo-textile bags shall be of top loading fabric-type made from woven polypropylene material. The center to center spacing between a set of geo-textile bags shall be kept minimum possible but in no case shall it exceed 7.0 meters in case 18 pipeline and 5.0 meters in case of 12 pipeline and below.

2.2 2.3

b. c.

2.4 2.5

Manufacturer shall take prior approval from Owner on details of geo-textile bags and design calculations. The fabric weights to be used in the pipeline should be from a manufacturer with a minimum of 5 years continuous, successful experience in production of geo-textile fabric weights for pipeline buoyancy control application. Manufacturing plants must be an ISO 9002 certified facility to ensure consistency in quality. The proposed bags and associated straps etc. shall not be detrimental to the pipeline coating in any manner. Repair of bags, in any manner is not permitted.

2.6 2.7

3.0 MATERIAL
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3.1

The body fabric must be treated for UV protection and longevity. The weight of the body fabric must be a minimum of 400 gms/m .
2

3.2 3.3 3.4 3.5

All material used in the fabrication of geo-textile bags such as webbing, lifting loops, threads etc. shall be polypropylene material. All webbing must have a minimum individual tensile rating of at least 2268 kg. With a combined safety rating of 4 times the capacity. Body fabric must have a maximum elongation rating of 15% and be stable within a pH range between 2 to 12. All testing should be as per ASTM or equivalent standards

4.0 DELIVERY, STORAGE AND HANDLING


4.1 4.2 Geo-textile bags shall be delivered on pallets with a black protective cover for easy handling and storage. Protective cover to be maintained to ensure the proper protection from oil, dirt and sunlight.

5.0 MARKING
5.1 On each black protective cover the following shall be marked by suitable means Maintain cover or provide separate cover on bags until use. Ensure proper protection from oil, dirt, sunlight etc. Each geo-textile bag shall be marked by indelible paint or other suitable methods with the following minimum information: a. b. c. d. e. Product model Name of Manufacturer Dimensions of bag in mm. Weight carrying capacity (Total weight when filled) Year, month of manufacture and product batch number

5.2

6.0 OTHER TECHNICAL REQUIREMENTS


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6.1

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

7.0 INSTALLATION
7.1 7.2 The geo-textile bags shall be filled by using proper sized filling hoppers with appropriate stone as recommended by manufacturer. While picking up fabric weights for transportation, it shall be ensured that all hooks and clevises are free of large, sharp defects that may damage the lift straps. Only suitable devices or bag type slings shall be used during lifting. Trailers with rails or strapping to secure the load shall be used for transportation to site. The bags shall not be stacked. Weights are to be kept in upright and leaning in supported position in ROU for easy accesses to the lifting loops. Extra trench width and depth shall be excavated to accommodate the Geo textile bags. Backhoe or side boom shall be used for installation of the same.

7.3 7.4 7.5

8.0 DOCUMENTATION
Following documents shall be submitted for review before installation of geo-textile bags 8.1 All necessary calculations to demonstrate the suitability of proposed geo-textile bags for pipeline anti-buoyancy measures under the specified design conditions. The manufacturer shall provide an undertaking that the proposed geo-textile bags are suitable for 18/12 & 10, 3 layer polyethylene coated line pipe. Three layers PE coating shall be minimum 2.2 mm thick. All details of proposed geo-textile bags (such as dimensions, material used etc.) shall be furnished. Contractor shall highlight any special features if any. General arrangement drawings of all items viz. set of geo-textile bags, hopper, loading arrangement etc. Details of all associated equipments (hoppers etc), spares, tools etc required to fill, transport and install geo-textile bags on the pipeline.
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8.2 8.3 8.4

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8.5

Complete descriptive technical catalogues describing the materials offered along with samples of geo-textile bags, its properties, testing results and installation instruction as applicable specifically to the project, Specific storage and handling instructions. Manufacturer shall highlight any precautions / safety measures to be taken.

8.6

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SPECIFICATION 0001-01-04-02-002

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TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING


SPUR LINES OF CHAINSA-JHAJJAR PIPELINE

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TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

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TABLE OF CONTENTS
1.0 2.0 3.0 3.1 3.2 4.0 5.0 6.0 INTRODUCTION RESPONSIBILITY OF CONTRACTOR SCOPE OF WORK Precommissioning activities Commissioning related activities DOCUMENTATION SPARES AND COMSUMABLES SAFETY

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TECHNICAL SPECIFICATION FOR PRECOMMISSIONING AND COMMISSIONING

SPECIFICATION 0001-01-04-02-003

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1.0 INTRODUCTION
This specification covers the minimum technical requirements for: i.) Precommissioning of :
Sl. Pipeline Tap-off Point Size(Inch) X Length (Km)

Sultanpur Haryana) to Neemrana (Rajasthan) Spur Line to Bhiwadi

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

18 X 85.28

Tap-off point at Chainage 12 X 9 31.6 Km in Sultanpur Neemrana Line Tap-off point at Chainage 61.14 Km in Chainsa-Jhajjar line 10 X 5.4

Hayatpur to Manesar Hayatpur to Gurgaon

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

ii.) Commissioning activities consisting of Drying, Inertisation, Gas-in / Commissioning, stabilization and 72 hours run of Pipeline as mentioned above in Table 1.0 - ( i ) Contractor, along with his bid documents, is required to submit the following: Execution plan and method statement for pre-commissioning and commissioning activities. Past experience of pre-commissioning and commissioning activities carried out for a similar pipeline system / network. Plan to engage an agency / subcontractor for these activities (if envisaged). Organization charts of bidders proposed pre-commissioning and commissioning team indicating the positions with the required qualifications and experience. Clause wise list of deviations, if any, from this technical specification. In the
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absence of this, it shall be considered that the bidder has no deviation. Questionnaire as given in Appendix-I duly filled by bidder.

2.0

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

2.1

Precommissioning In order to execute and perform pre-commissioning activities, the contractor shall be responsible for (but not limited to): Carrying out precommissioning checks of the underground pipeline system including above ground piping at dispatch station and at receipt stations, Sectionalising Valve (SV) stations, CGS/ PRS Station, tap-off / hook-up piping and all terminals. Dewatering of the pipeline. Flushing and dry air blowing of under ground & above ground piping at dispatch and receipt stations, SV stations, all Terminal stations and hookup point. Swabbing of pipeline. Low pressure leak check (with air) for the aboveground section of the pipelines. Supply and supervision of manpower for precommissioning. Supply and operation of machinery & equipment for precommissioning. Supply and use of materials precommissioning activities. and consumables as required for the

Design and supply all temporary line connections, pig launcher/receiver, valves, instruments, manpower etc. as required during various operations. Preparation of detailed precommissioning procedures, activity schedules, bar charts, schemes etc. This shall include preparation of detailed procedures for dewatering, flushing, swabbing, and low pressure leak check and shall address the sequence and
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methodology describing all operations, data on materials, equipment, instruments, consumables, communication systems, necessary calculations, detailed time schedule and organization chart. All necessary work to perform the job successfully including all modifications that would be required. The contractor shall demonstrate to the COMPANY (for COMPANYs approval) the successful completion of all of the above-mentioned activities. In the event of any detail, which is not fully addressed, contractor should warrant that work shall be performed in accordance with the relevant codes, Company's specifications and the best recognized Engineering guidelines and practices being followed in the on-shore pipeline industry. 2.2 Drying, Inertisation, Gas-in / Commissioning, stabilization and 72 hours run In order to execute and perform commissioning related activities, the contractor shall be responsible for (but not limited to): Drying of the underground pipeline and above ground piping system at dispatch and receipt stations, above ground piping system at all Terminal stations, CGS/PRS Station, SV stations and hook-up / tap-off points to a water dew point of 0C at atmospheric pressure, and maintain this dew point in the pipeline, till inertisation and gas-in activities commence. Commissioning checks including Safety review prior to start of commissioning activities to achieve Ready for commissioning status for underground pipeline and above ground piping system at dispatch and receipt stations, above ground piping system at IP stations, SV stations and hook-up / tap-off points. Inertisation of the pipeline system including above ground piping system at dispatch and receipt stations, above ground piping system at all Terminal stations, CGS/PRS Station, SV stations and hook-up / tap-off points. Gas-in activities including pressurization, carrying out high pressure leak checks and establishment of flows in the pipeline system including above ground piping at dispatch and receipt stations, SV stations, all Terminal station, CGS/ PRS station and hook-up points. Stabilization and 72 hours run of the pipeline system.
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Supply and supervision of manpower for commissioning. Supply and operation of machinery & equipment for commissioning. Supply and use of materials and consumables as required for the commissioning activities. Design and supply all temporary line connections, pig launcher/receiver, valves, instruments, manpower etc. as required during various operations. Preparation of detailed commissioning procedures, activity schedules, bar charts, schemes etc. This shall include preparation of detailed procedures for Drying, Inertisation, Gas-in / commissioning operations, high pressure leak check operations, pressurization, establishing flows and 72 hours run of the pipeline system, and shall address the sequence and methodology describing all operations, data on materials, equipment, instruments, consumables, communication systems, necessary calculations, detailed time schedule and organization chart. Ensuring all communication facilities are in place and in proper working condition prior to start of commissioning activities of the pipeline system. All necessary work to perform the job successfully including all modifications that would be required. The contractor shall demonstrate to the COMPANY (for Companys approval) the successful completion of all of the abovementioned activities. In the event of any detail, which is not fully addressed, contractor should warrant that work shall be performed in accordance with the relevant codes, Company's specifications and the best recognized Engineering guidelines and practices being followed in the on-shore pipeline industry.

3.0

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

3.1

Precommissioning activities

3.1.1 Precommissioning checks


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Pre-commissioning checks shall be carried out for the pipeline system to ascertain that the pipeline system has been mechanically completed in all respects. These checks shall cover the main pipeline including distribution network system, dispatch and receipt stations, all Terminal Stations, CGS/ PRS stations, sectionalizing valve stations and the hook up points. The pre-commissioning checks shall include the following: A) System Checks The entire facilities shall be checked against the latest P&ID's, Engineering and Vendor drawings / documents and other design specifications. Any shortcomings observed shall be listed down in the form of punchlists and duly attended. B) Checking of Field Instruments All the field instruments like actuated valves, control valves, shutdown valves, transmitters, solenoid valves, shut down switches, alarms etc. shall be checked physically and also for their intended application by simulating the operating condition. It will also include checking of different meters, gauges, action of actuated valves, control valves, shutdown valves etc. C) Survey of the Pipelines This shall be performed to confirm that proper fittings/supports, Cathodic protection system, route markets, warning signs, fencing around SV stations, crash barriers etc. have been installed along the pipeline. D) Checking of Communication System This is to check that there is proper communication with adequate back-up power to ensure uninterrupted communication. E) Checking of Electrical Distribution System This is to ensure safety and also to ensure an uninterrupted power supply during startup and normal pipeline operation. F) Checking of Instruments, Controls & Interlocks This is to check that instrument controls and interlocks are functional as per the normal operating conditions.
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G) Checking of Utilities This is to check that utilities like power, nitrogen, UPS system, instrument air, etc. are available prior to start-up. H) Any other checks as may be considered necessary. 3.1.2 Dewatering 3.1.2.1 General Dewatering of a pipeline section shall be done subsequent to the hydro-test of the respective pipeline section. During the dewatering operation, the major quantity of hydro-test water shall be removed from the main pipelines and distribution network. It is the responsibility of the contractor to develop suitable dewatering procedure and submit the same for Company's approval. The disposal of the water shall be performed such that no harm is done to the environment and the Dewatering procedure should indicate this disposal methodology. 3.1.2.2 Operational requirements The dewatering operation for pipeline shall consist of a number of dewatering pig runs and dry air shall be used as propellant for pig trains. Bi-directional cup pigs shall be used and will be suitable for traversing the entire length of the pipeline/pipe segment being dewatered. Contractor shall ensure that all the pigs are designed to prevent damage to the pipelines internal coating (if any). The contractor shall propose the minimum speed and the backpressure of the pigs in order that continuous operation will be performed without the pig getting stuck. Contractor shall submit all the calculations regarding this procedure and a contingency plan for implementation in case the pigs get stuck. Contractor shall provide a suitable compressor for oil-free air with sufficient capacity and pressure. Upon arrival of the pigs at the receiving end, the Contractor in the presence of Company's representative shall remove the pigs without delay. Flushing of aboveground piping

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Flushing of above ground piping at dispatch and receipt stations, SV stations, hook-up / tap-off points and IP stations shall be done with water to remove debris from within the piping and then with dry air to remove the residual amount of water from the aboveground piping. Acceptance criteria Before proceeding to the next stage of operations, Contractor shall ensure that bulk of the water has been removed from the pipeline system. Contractor shall specify when the dewatering phase (for the underground pipeline) and flushing and dry air blowing (for above ground piping) is finished and shall obtain approval of the company before proceeding to the next phase. 3.1.3 Swabbing 3.1.3.1 General The swabbing operation, which shall be done subsequent to the dewatering operation, is meant to reduce the remaining water in the pipeline to acceptable condition and to ensure removal of free water left inside the pipeline prior to final drying, Inertisation and commissioning of the Pipeline system. This is done by driving number of foam pigs propelled by oil free compressed dry air, which can pick up free water in the pipeline. Hence for swabbing, air compressors of required capacity, after-coolers and dryers should be deployed by the contractor. Contractor may suggest alternate methodology for Swabbing operation. The swabbing activity is precursor for drying of the pipeline and is basically to reduce duration of drying. The contractor shall submit the detailed procedure and the duration of the swabbing operation and obtain approval of the company before starting the operation. 3.1.3.2 Acceptance criteria The Contractor shall ensure that swabbing operation is considered to be completed when it is considered that there is no free water left in the pipeline.This shall be subject to Companys approval. 3.2 Commissioning related activities

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3.2.1 Drying 3.2.1.1 General The pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal station, CGS/ PRS stations and hook-up / tap-of points needs to be dried prior to charging natural gas. Drying is required to prevent internal corrosion of the pipeline & to meet the supply specification and also as a means of preservation of the pipeline sections subsequent to the precommisisoning activities. The pipeline shall be dried by using super dry air / vacuum method or by any other suitable method. Contractor shall submit the detailed procedure and the duration of the drying operation and obtain Company's approval on the same prior to start of the drying operation. Commissioning contractor shall assess any requirement of swabbing for entire pipeline to reduce the time for drying and shall carryout such activity. 3.2.1.2 Acceptance criteria Contractor shall ensure that drying operation is complete before proceeding to the next step of inertisation. The drying of the pipeline system shall be considered to be achieved on attaining a water dew point of 0C at atmospheric pressure and this water dew point in pipeline shall be continuously maintained till inertisation or commissioning of the pipeline. 3.2.2 Low Pressure leak check for aboveground piping

3.2.2.1 General
The aboveground piping sections of the pipeline system shall be checked for leaks at flange points of piping and equipment, instrument impulse tubing points etc. This shall be done by pressurizing the system piping / equipment with dry compressed air (for this purpose, oil free air compressors shall be used) and testing the system by means of soap solution for leaks. The contractor shall submit the detailed procedure and the duration of the leak check operations and obtain approval of the company before starting the operation. 3.2.2.2 Acceptance criteria

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SPECIFICATION 0001-01-04-02-003

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The leak check operation shall be considered to be completed when the piping system / equipment is free of leaks when tested at a pressure of 6.0 Kg/cm g. This shall be subject to Companys approval. 3.2.3 Ready for Commissioning After completion of drying activities and safety review prior to startup, Contractor shall notify the Company that the systems associated with the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, al Terminal Station, CGS/ PRS stations and hook-up / tap-of points are ready for gas-in/commissioning. 'Ready for commissioning status' shall be jointly reviewed by Company and Contractor and final clearance for start-up shall be given by the Company. After such joint assessment, if all the criteria are met, it will then be declared that the pipeline system has reached a stage of 'Ready for Commissioning'. 3.2.4 Inertisation 3.2.4.1 General Contractor shall carry out inertisation of the entire pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points). 3.2.4.2 Operational requirements During the Inertisation operation, the dry air left in all the pipeline shall be replaced by dry nitrogen before admitting the natural gas into the pipeline for safe commissioning. Depending on the commissioning plan / strategy, sections of the pipeline system may be taken up for commissioning in steps. One of the suggested methods for Inertisation of the underground pipeline is by the usage of nitrogen slugs separated by pigs. Depending on the length of the pipeline portion to be taken up for commissioning, the amount of the nitrogen used may vary. In general, the totalised length of the nitrogen slug train must be at least 10% of the total length of the pipeline under consideration. The last pig in the pig train shall be propelled by natural gas (during commissioning stage of the pipeline). In case Vacuum drying procedure is adopted, the pipeline can be inertised under vacuum condition, followed by gas charging to reduce the time for commissioning activities.
2

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SPECIFICATION 0001-01-04-02-003

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For above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points, the piping shall be purged with nitrogen till the residual oxygen content in the piping is below 1% (vol/vol). Nitrogen required for Inertisation purpose of the pipeline and aboveground piping shall be supplied by the contractor and should be of purity level 99.9% or above. Nitrogen gas at ambient temperatures (AND NOT LIQUID NITROGEN) and in completely vaporized and gaseous state shall be used as the inertising medium. In case the source of gaseous nitrogen is from liquid nitrogen tankers, then all precautions (including verification of the lowest tolerable temperature of all components in the system under commissioning) should be ensured. The contractor shall submit the detailed procedure (in line with the above suggested method or any other acceptable one) and the duration of the inertisation operation and obtain approval of the company before starting the operation. Inertisation shall be followed immediately by charging of pipeline by natural gas. 3.2.4.3 Acceptance Criteria Inertisation of all the pipeline may be accepted to be complete when the required quantity of nitrogen has been introduced into the pipeline. The contractor has to ensure this condition for safe commissioning of the pipeline. For above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tapof points, the inertisation may be accepted to be complete when the residual oxygen content in the piping is below 1% (vol/vol). 3.2.5 Safety review prior to start of Commissioning activities A pre-startup safety review of the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal stations, CGS/ PRS stations and hook-up / tap-of points shall be carried out by the Contractor before permitting entry of natural gas into the new pipeline facility. Company / Company's representative shall also participate in the pre-startup safety review. 3.2.6 Gas-in/Commissioning and Stabilization 3.2.6.1 General Contractor shall carry out gas-in and commissioning activities of the entire pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, IP stations and hook-up / tap-of points.
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3.2.6.2 Operational requirements During introduction of natural gas into the pipeline, natural gas shall be the motive fluid for driving the last pig of the nitrogen slug train. The pig train speed shall be maintained at 3 to 4 Km/hr. Maintenance of proper backpressure shall control pig train speed. Venting shall be controlled at the pig-receiving end to achieve the desired dynamics. In this fashion, slowly the desired portion of the pipeline shall be commissioned. Alternatively contractor may propose procedure for introduction of gas in pipeline under vacuum condition after inertisation with Nitrogen. Subsequently, the pipeline system shall be slowly pressurized upto its operating conditions and high pressure leak checks of the pipeline system at flange points, instrument points etc. shall be carried out with soap solution at regular intervals during the course of pressurization of the pipeline system. Once the pipeline system is pressurized at its operating conditions, normal gas flows shall be established in the pipeline system. The contractor shall submit the detailed procedure (in line with the above suggested method or any other acceptable one) and the duration of the commissioning operation and obtain approval of the company before starting the operation. Commissioning shall also include establishing the process control parameters first at turn down & then at design value stipulated in the process package along with supplementary instructions, if any, from Company / Companys Representative. 3.2.6.3 Acceptance Criteria The system shall be considered to be commissioned successfully when the pipeline system including the underground pipeline and the above ground piping at dispatch and receipt stations, SV stations, all Terminal Station, CGS/ PRS stations and hook-up / tap-of points is charged with natural gas, is free of leaks and run successfully at stable operating conditions with instrumentation / control systems process utilities and support systems taken on line for a minimum period of 72 hours. The commissioning of pipeline system shall include commissioning of branch lines and associated facilities including auxiliary facilities and aboveground piping.

4.0

DOCUMENTATION
Contractor shall submit for approval of the Company, the complete description, detailed procedures and time schedule for all of the following activities: Pre-commissioning checks

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Dewatering Flushing Swabbing Drying Low pressure leak check of aboveground piping system with dry compressed air Inertisation Gas in and commissioning activities (including pressurization of pipeline system, high pressure leak check, establishment of flows and 72 hours run). All these documents should be prepared covering all aspects of HSE, quality assurance and quality control plans. Contractor shall ensure that his documents are related to as-built conditions of the pipeline and structure involved. Documents shall also contain all safety plans, procedures, to be followed while carrying out the activities. Upon successful completion of the work, contractor shall prepare a final report of the work which shall include necessary charts, diagrams, graphs, calculations, recordings, daily logs, measurements, details of the operation, etc. Report shall also include all certificates of calibration of instruments required, together with records of calibration performed at site prior to the start of any operation and the approved precommissioning and commissioning formats and checksheets. 5.0

SPARES AND CONSUMABLES


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

6.0

SAFETY
Contractor shall follow the safety practices during execution of precommissioning and Commissioning works as detailed in the scope of work. He shall also maintain and follow all safety practices equivalent or better than those being practiced by the industry during pre-commissioning and commissioning activities.

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APPENDIX-I QUESTIONNAIRE {PRIVATE }CLAUSE DESCRIPTION OF CLAUSE NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 SCOPE DEFINITIONS MANUFACTURER REPRESENTATIVE DOCUMENT FOR PRECOMMISSIONING AND COMMISSIONING OTHER REQUIREMENTS REVIEW/CHECKLISTING/INSPECTION/COORDINATION COMMISSIONING CONSUMABLES SPECIAL REQUIREMENTS SAFETY NOT REMARKS AGREED [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

AGREED [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

NOTE: 1) 2)

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

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

GAIL (INDIA) LTD NEW DELHI

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

DOCUMENT No. S-04-02-001

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Abbreviations: ASTM API ID LSAW HAZ NDT NPS OD WT American Society for Testing and Materials American Petroleum Institute Inside Diameter Longitudinal Seam Submerged Arc Welded Heat Affected Zone Non Destructive Testing Nominal Pipe Size Outside Diameter, Specified Wall Thickness, Specified

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

DOCUMENT No. S-04-02-001

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CONTENTS 1 2 5 6 7 9 10 11 12 14 (New) APPENDIX-B APPENDIX-C APPENDIX-F SR 5 SR 6 SR 19 APPENDIX-H APPENDIX-I ANNEXURE-I (New) ANNEXURE-II (New) ANNEXURE-III (New) FIGURE 6.2.6.1 FIGURE 6.2.6.2 FIGURE 7.8.3 FIGURE9.8.5.2
GAIL (INDIA) LTD NEW DELHI

SCOPE REFERENCES PROCESS OF MANUFACTURE AND MATERIAL MATERIAL REQUIREMENTS DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES INSPECTION AND TESTING MARKING COATING AND PROTECTION DOCUMENTS INSPECTIONS OF FIELD TESTS & WARRANTY REPAIR OF DEFECTS BY WELDING (NORMATIVE) REPAIR WELDING PROCEDURE (NORMATIVE) SUPPLEMENTARY REQUIREMENTS (NORMATIVE) FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4 OR LARGER DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER. ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE PURCHASER INSPECTION (NORMATIVE) MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) MANUFACTURING PROCEDURE SPECIFICATION FIRST DAY PRODUCTION TESTS INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING METALLOGRAPHIC SPECIMEN EXTRACTION PLAN LOCATIONS FOR HARDNESS MEASUREMENT PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM
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1.0 1.1

SCOPE PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinal seam submerged arc welded steel line pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and makes restrictive amendments/ Supplements to API Spec. 5L. Unless modified and or deleted by this specification, the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering as that of API Spec 5L in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of Specification 5L, Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2.

1.2

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

1.3 1.4

GRADES This specification is applicable to PSL 2 line pipes of grade B through X70. DIMENSIONS This specification shall be applied to line pipe of size 16 through 48 (both sizes included)

2.0 2.1

References The latest editions (edition enforces at the time of issue of enquiry) of following additional references are included in this specification: ASTM ASTM E 92 ASTM E 112 BS BS 5996 ASME IX ASME B31.8
GAIL (INDIA) LTD NEW DELHI

: Test Method for Vickers Hardness of Metallic Materials. : Standard Test Methods for Determining Average Grain Size.

: Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats based on Ultrasonic Testing. : Boiler & Pressure Vessel code: Welding & brazing quality. : Gas Transmission & Distribution piping system.
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OISD 141 API RP 5 L1 5.0 5.1

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

Process of Manufacture and Material PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process Type of Pipe per para 5.1.3.5 Type of Seam Weld para 5.1.4.3 : : : Submerged Arc Welding as per para 5.1.2.2.1 Longitudinal Seam Submerged Arc Welded Pipe as Submerged Arc Weld (Longitudinal Seam) as per

5.2

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

5.3

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

5.4

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

6.0 61

Material Requirements CHEMICAL PROPERTIES The chemical composition of each heat of steel on product analysis shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled.
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6.1.1 Chemical Composition

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Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element C Mn Si S P Al Nb V Ti Cr Mo Cu Ni N B Note: g (New) i. ii. iii. V+Nb+Ti shall not exceed 0.1 5% Cu-+-Ni shall not exceed 0.40% Al/N shall be min. 2 Product Analysis (percent by weight ) 0.16 1.50 1.60 0.15 0.45 0.015 0.02 0.07 0.05 0.08 0.04 0.06 0.20 0.10 0.35 0.20 0.012 0.0005 max. max. max. max. max. max. max. max. max. max. max. max. (For Grade B toX60) max. (For Grade X65 to X70) max. max. (For Grade B min. max. to X52) max. (For Grade X56 to X70)

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

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

DOCUMENT No. S-04-02-001

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6.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analysed and reported, even if those are not purposely added but are present as residuals only. 6.1.3 6.1.3.1 Carbon Equivalent (PSL 2 Only) Calculation of Carbon Equivalent Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 6.1.3.2 Maximum Carbon Equivalent

For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits: CE (Pcm ) CE (IIW ) 6.2 0.20 % 0.40 %

MECHANICAL PROPERTIES The finished pipe (after all heat treatment and expansion or sizing operations) shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under; API Spec 5L Grade Up to and including X46 X52 TO X65 X70 and Above Permissible in excess of SMYS. Psi (MPa) 19,000 (131) 22,000(152) 20.000 (138)

6.2.1 Tensile Properties

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal of finished expanded pipe shall not exceed 0.90, when tested using cylindrical all weld specimen. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the formula given in foot note (a) of Table-3B and shall comply with the minimum values of
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API Spec 5L. Appendix D. However elongation in no case shall be less than 20%. API Spec 5L, Appendix D stands modified accordingly. 6.2.5 6.2.5.2 Fracture Toughness Tests Charpy Impact Tests for PSL 2

For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. 6.2.5.3 Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area in accordance with Supplementary Requirement SR 5A of API Spec 5L and as modified in this specification shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order. Drop Weight Tear Test in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size, grade and wall thickness. 6.2.6 Metallographic Examination 6.2.6.1 A test specimen for metallographic & hardness examination shall be taken transverse to the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) whichever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen extraction shall be as per Fig. 6.2.6. 1 of this specification. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that proper fusion has been obtained for the full thickness, and there is proper interpretation of passes, their alignment and texture of weld zone. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's Representative. 6.2.6.2 Vickers hardness tests shall be carried out on each specimen taken for metallographic examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this specification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected Zone shall start as close to the fusion line as possible. The resulting Vickers hardness value at any point shall not exceed 248 HV10, Modalities of re-test shall be in accordance with para 9.12.2 of API Spec. 5L. 7 7.2 Dimensions, Weights, Lengths, Defects and End Finishes DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6C, Appendix E. API
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Spec 5L Table 7 stands modified accordingly. Size 16 and < 20 20 and 36 >36 Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable on the inside diameter. The inside diameter, based on circumferential measurement, over a length of 100 mm from the end shall comply with the tolerances specified in API Spec 5L. Inside diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum inside diameter at pipe ends, shall not exceed the following: Size <36 : >36 : Tolerance 0.5%of OD < 5mm Tolerances 3 mm + 3 mm, 0.25% of specified OD 3 mm.

Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundness tolerances apply to maximum and minimum diameters as measured with a bar gauge, caliper or device measuring actual maximum and minimum diameter. Each pipe shall be measured for conformance to above requirements. All dimensions and tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). 7.3 WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wail thickness shall be (+) 15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

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

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7.5

LENGTH

All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0m. API Spec 5L Table 11 shall not be applicable. Overall length tolerance shall be (-) 'Zero and (+) One pipe length to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurements shall be recorded. 7.6 STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.7 7.8 7.8.1 JOINTERS Jointers on pipes are not permitted. WORKMANSHIP AND DEFECTS Dents

Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable. 7.8.2 Offset of Plate Edges All pipes shall be checked for offset of plate/ skelp edges. Offset shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.8.3 Out-of-Line Weld Bead for Pipe with Filler Metal Welds A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment shall be measured on radiographic film and calculated using the formula (a+b)/2 where 'a and 'b' are the relative offsets of the outside edges of the seam (refer Figure 7.8.3 of this specification). All pipes shall be checked for out-of-line weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out on metallographic examination specimen as stated at para 6.2.6, 7.8.4 Height of Outside and Inside Weld Beads - Submerged Arc Welds The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height using a template having a cut out for weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum).
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7.8.8

Hard Spots

Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot shall be removed as a cylinder. 7.8.9 Cracks, Sweats and Leaks Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the requirement of API Spec 5L para 9.9 (c) or (d). 7.8.10 Laminations Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of detects on the plate/skelp shall be as per para 9.8.5.4 of this specification. 7.8.12 Undercuts Undercutting not classified as minor shall be considered a defect. Disposition shall he as follows: 1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12 % of the specified wall thickness shall be removed by grinding in accordance with API Spec 5L para 9.9 (a) and as modified in this specification. 2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12 % of the specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d). 7.8.14 Other Defects Any imperfection (measured from the surface) with a depth greater than 5% of the specified wall thickness of the pipe shall be considered a defect and shall be repaired in accordance with para 9.9 and as modified in this specification. 7.8. 15 Peaking (New)Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6 mm. Each pipe shall be checked for conformance to above requirement. Peaking shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). Pipes not complying with these requirements shall be disposed off as per API Spec. 5L para 9.9 (c) or (d). 7.9 7.9.1 7.9.3 PIPE ENDS General Pipes shall be furnished with plain ends. Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L. In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metal
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and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall be rebevelled and rectification by filing or grinding shall not be done. 7.9.6 Bevel Protectors (New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they can he re-used by coating applicator for providing on externally anti-corrosion coated pipes subsequent to coating of line pipe. 9.0 9.2 Inspection and Testing TESTING OF CHEMICAL COMPOSITION

9.2 1 Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production. 9.2.2 Product Analysis 9.2.2.1 Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat are also represented. 9.2.2.2 Sampling Method 9.2.2.2.2 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from plate/skelp may be used provided the traceability of samples is guaranteed. 9.3 9.3.1 TESTING OF MECHANICAL PROPERTIES Tensile Tests

Tensile property shall be determined from specimen removed from pipe which has been subjected to all mechanical operations. 9.3.1.2 Tensile Testing Frequency Tensile tests shall be made at the frequency of one test per inspection lot as shown in Table 13, except as modified below: . Table 13: Maximum Inspection Lot Size for Tensile Testing For Size 12, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13 shall also be applicable.

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9.3.1.4 9.3.1.5

Transverse Tensile Tests Weld Tensile Tests

The transverse tensile tests shall be carried out on flattened rectangular specimen. Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first day production test as specified in Annexure-II of this specification to determine the yield strength, ultimate tensile strength and elongation. The cylindrical all weld specimen shall have gauge length, L = 5d, where; L = gauge length (mm) D = diameter of the test specimen (mm) The results of the test shall meet the minimum requirements of the plate/skelp with regard to yield, tensile and elongation parameter. 9.3.5 9.3.5.1 Fracture Toughness Tests Charpy Test Specimens

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

The minimum test frequency shall he one test (a set of three specimen each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. 9.4 9.4.1 HYDROSTATIC TESTS Hydrostatic Test Requirements

Hydro test shall be carried out after cold expansion. Test pressure shall be held for a minimum period of I5 seconds for all sizes and grades of pipes. 9.4.2 Verification of Hydrostatic Teat The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and record shall be maintained. Calibration record shall be
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furnished to the purchasers representative on request. 9.4.3 Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5L para 9.4.3 (Note 2). 9.4.5 Burst Test

(New)Burst test shall be done on each type of pipe for each size on lowest thickness. Burst pressure & location of failure shall be recorded. Technical audit shall be carried out by OWNER / OWNERS representative during manufacturing. Minimum Burst Test pressure shall not be less than the actual tensile stress factor computed pressure. 9.5 DIMENSIONAL TESTING

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

All pipes shall be visually examined both externally and internally (to the extent feasible) and shall be free of defects in the finished condition. 9.8 NON DESTRUCTIVE INSPECTION

The Purchaser reserves the right to depute its Representative(s) to perform inspection and witness tests in all phases of manufacturing and testing starting from steel making to finished line pipe ready for shipment. Manufacturer shall comply with the provisions regarding inspection notice, plant access, compliance and rejection mentioned in Appendix H of API Spec 5L. The Manufacturer shall give the Purchaser reasonable notice of the starting date of normal production and the work schedule. Any action or omission on part of Purchaser's Representative shall not relieve the Manufacturer of his responsibility and obligation to supply material in strict accordance with this specification. 9.8.1 Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. Inspector Qualification
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Acceptable qualification for NDT inspectors shall be as specified below: i. For UT For UT, at least one level III qualified inspector shall be available to the mill for overall supervision. A level II inspector is required for shift supervision, manual weld inspection and calibration of all systems (both manual and automated). ii.For all other NDT methods Evaluation of indications : Supervision 9.8.3 : Level I, II, III inspector Level II or Level III inspector (in case evaluation is by Level I inspector)

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of weld seam of cold expanded pipe shall be performed after cold expansion and hydrotesting. Plate/Skelp Inspection The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over a width of at least 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp shall be ultrasonically tested for laminations using an oscillating or straight running pattern of probes, so as to provide inspection coverage of at least 20% of the plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination, the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Pipe Ends Inspection The full circumference of both ends of each pipe after bevelling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. In addition, full circumference of both ends of each pipe shall be 100 % ultrasonically tested over a circumferential width of at least 50 mm with angular probes to detect cracks. In case of non availability of angular probes at the mill, the full circumference of both ends of each pipe shall be inspected with magnetic particle technique over a circumferential width of at least 50 mm to detect surface cracks. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table 24) using
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automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be re-examined by radiography. If during production, repeated ultrasonic indications occur requiring re-inspection by radiography and it appears from radiographs that the nature of defects causing the ultrasonic indications cannot be definitely established, the Manufacturer shall prove by other inspection methods (e.g. by making some cross-sections in accordance with para 6.2.6 of this specification at locations where such indications occur near the end of the pipe) to the satisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 9.8.3.1 Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged-arc weld seam shall be radiographically examined for a minimum distance of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be recorded. 9.8.4 9.8.4.1 Radiological Inspection-Weld Seams Radiological Inspection Equipment

The homogeneity of weld seams examined by radiological methods shall be determined by means of X-rays directed through the weld material in order to create a suitable image on radiographic film. The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table 2 of ASTM E 94, with minimum density greater than 1.8 measured in connection with radiographic image of the welding and shall be suitable to allow a sensitivity of at least 1 .8 percent of nominal wall thickness. 9.8.4.2 Radiological Sensitivity Reference Standard The reference standard shall be ISO wire-type image quality indicator described in 9.8.4.4. 9.8.4.8 Defects Observed During Radiological Inspection Defects in the weld such as cracks, slag inclusions, porosity and defects in the pipe material shall be removed by cutting off the section of pipe containing these defects. The remaining defects-free section of the pipe will be acceptable provided its length is within the specified minimum length, the weld at the new pipe end contains no defects other than those permitted. 9.8.5 9.8.5.1 Ultrasonic and Electromagnetic Inspection Equipment
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All automatic ultrasonic equipment shall have an alarm device, which continuously
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monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre. 9.8.5.2 Ultrasonic and Electromagnetic Inspection Reference Standards The reference standard (calibration pipe) shall have the same specified diameter and wall thickness as specified for the production pipe being inspected and shall be of sufficient length to permit calibration of ultrasonic inspection equipment at the speed to be used in normal production. The reference standard (calibration pipe) shall also be of the same material, type and have the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches/holes as per Figure 9.8.5.2 of this specification and as given below: Two longitudinal inside notches of type N 5 at both edges of weld seam. Two longitudinal outside notches of type N5 at both edges of weld seam.

Two longitudinal notches of type N5 at the centre of the weld seam, one outside and one inside. Two transverse notches of type N5 across the weld seam, one outside and one inside. A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm The reference standard for plate/skelp UT shall contain continuous machined notch of 8 mm width x t depth, where t is the specified wall thickness. The reference standard for plate/skelp edge UT and pipe ends shall have inch dia FBH X1/2 t depth, where 't' is the specified wall thickness. The calibration shall be performed at following intervals: a. b. c. At the beginning of each operating shift (12 hours maximum). At least once during each operating shift (12 hours maximum). Every time the running of the system gives rise to doubts on its efficiency.

If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or plate/skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4 Acceptance limits 9.8.5.4.1Plate/Skelp Edges
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(New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. 3. Maximum length of imperfection in any direction shall not exceed 30 mm. Maximum area of individual imperfection shall not exceed 500 mm2.

4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.5.4.2 Remaining Plate/Skelp (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8 mm. (The length is the dimension at right angles to the scan track-and the width is the dimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per I m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7 Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be recorded. 9.9 DISPOSITION OF PIPE CONTAINING DEFECTS a. The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with 9.9 (c) or (d). b. Repair welding on parent metal is not permitted. In addition to all NDT requirements random radiography of0.1%the total length shall be done. The area to be radiographed shall be at the sole discretion of the Third Party Inspection
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Agency. 9.10 9.10.3 TEST METHODS Guided-bend Test

One face and one root guided bend weld test shall be made on samples cut from pipe. The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. The dimension 'A' in guided bend test shall not exceed 4.0 times the thickness of the specimen. 9.10.4 Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification. 9.12 9.12.1 RETESTS Recheck Analysis

Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analyzed to meet the requirements of Table 2B of this specification. 9.12.6 Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then the entire pipe in that lot, with the exception of the original selected length, shall be considered to meet the requirement. 9.13 10 10.1 REPROCESSING Marking GENERAL This para stands cancelled.

Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be in English language and International System (SI) of units. Marking shall comply with Appendix I of API Spec 5L, and as modified in this specification. 11 11.1 Coating and Protection COATINGS

Unless otherwise specified in the Purchase Order, the pipes shall be delivered bare, free of any trace of oil, stain, grease and paint. Varnish coating shall be applied on the marking area. Bevels shall be free of any coating. 12 12.1 Documents CERTIFICATION
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Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix F Supplementary Requirement SR 15 shall also be submitted to Purchaser/Purchaser Representative during inspection at pipe mill. 12.2 RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/plate/skelp as well as pipe ends. 12.3 PRODUCTION REPORT (New) The Manufacturer shall provide six copies of production report in English language indicating at least the following for each pipe. International System of units (SI) shall be adopted. Pipe number Heat number from which pipe is produced Pipe length and weight. Pipe grade

The Manufacturer shall provide six copies of acceptance certificates which shall include the results of all tests required as per this specification and performed on delivered material giving details of, but not limited to, the following: All test certificates as per SR 15.1. Records of qualification of welders and procedures for repair welding. Certified reports of dimensional, workmanship and defects inspection. Data on test failures, rejected heats/lots, etc. All other reports and results required as per this specification.

The certificates shall be valid only when signed by the Purchaser's Representative. Only those pipes, which have been certified by the Purchaser's Representative shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the production report may consist of only test certificates required as per SR 15 of API Spec 5L and other test reports/results required as per this specification. 12.4 LINE PIPE TRACEABLITY DATA (New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer and shall include, but not limited to, the following:
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- All marking information - Data of skelp and pipe manufacture - All mechanical properties from test results - All dimensional records - All workmanship and defects inspection records - Final inspection and release date - Description and disposition of repairs - Load-out /dispatch date - Destination - Consignment details. 14 Inspection of Field Test & Warranty (New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not be postponed because of absence of the Manufacturer's Representative.

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APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.I. 2 B.3 WELD SEAM OF WELDED PIPE Procedure for Repair of Submerged-Arc and Gas Metal-Are Welds B. 1.2.1 Repaired welds shall be inspected both by X-ray and UT. B.3.1 The defective part of the weld shall be clearly marked on the pipe so that the defect can be easily located and repaired. B.3.2 a. b. Following requirements shall also be complied with for repair welding; No repair of weld seam is permissible after cold expansion. No repair of weld seam is permissible at pipe ends up to a length of 300 mm.

c. Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Maximum two repairs per pipe are allowed. d. e. f. B.3.4 (New) The Manufacturer shall also maintain a record of repairs carried out. The records shall include repair number, pipe identification number, welding procedure applicable and NDT details. Repair welding shall be executed only after specific approval by Purchaser No repair of a repaired weld is permitted. The repair weld shall be performed with a minimum of two passes. Representative for each repair.

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AFPENDIX- C REPAIR WELDING PROCEDURE (NORMATIVE) C.2 C.2.2 Repair Welding Procedure Qualification Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test The radius of male member of the jig used for guided bend teats shall be RA=2.25 t, where t is specified wall thickness of pipe. C.2.2.5 (New) For all pipes where fracture toughness test is specified, Charpy V-Notch impact test as specified shall be included in the Repair Welding Procedure Qualification. C.2.2.6 (New) Hardness test as specified in para 6.2.6.2 of this specification shall be included in the procedure qualification. The location of the hardness measurements is to be indicated taking into account the new HAZ of the repaired area.

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APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 or Larger SR 5.1 The Manufacturer shall perform Charpy V-notoh test for determining Shear Area. SR 5.3 The specimen shall be full sized or largest obtainable, sub size in case pipeline diameter and thickness does not permit full size specimen. SR 5.4 SR 5A Flattened specimen shall not be used. Shear Area SR 5.5 This para stands deleted. SR 5A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness, SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32F (0C). The average shear value of the fracture appearance of the three specimen shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%. Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements. Wherever 'heat indicated in API Spec 5L.SR 5A.3, SR 5A.4, SR 5A.5 and SR 5A.6 shall be replaced by Mot'. Lot shall be as per SR5A.1 as above. SR6 Drop Weight Tear Testing (DWTT) on Welded Pipe SR6.1 When required as per para 6.2.5.3 of this specification, fracture toughness for all pipe size, grades and specified wall thickness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer in accordance with the requirements of SR 6.2 thru SR 6.8 of API Spec 5L and as modified in this specification. SR 6.2 Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. Unless specified otherwise, the test shall be conducted at +32F (0C). SR 6.4 At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or mare for the specified test temperature. Note: Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by Hot'. Lot shall be as per SR6.2 as above. SR19 Additional Fracture Toughness Requirements (Transverse Charpy V-Notch) for PSL 2 Pipe SR 19.1 Except as allowed by SR 19.2 of API Spec 5L,, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and
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as modified in this specification, with a test temperature of 32F (0C) or at a lower temperature as specified in the Purchase Order. The required minimum all heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API Spec. SL, the minimum average absorbed energy value shall be 1.5 times that applicable for transverse specimen. The required minimum average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.

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APPENDIX-H PURCHASER INSPECTION (NORMATIVE) H.4 Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, tins shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.

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APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.1 General 1.1.1 Marking shall also include API monogram, Purchase Order number, item number, pipe number, wall thickness (mm), heat number and weight. 1.2 Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencil marking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. Paint used for stencil marking shall withstand a temperature up to 250C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator. 1.3 Sequence of Marking Actual pipe weight in kg shall also be marked. 1.3.5 Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends. 1.5 1.7 Length Actual length shall be marked in metres. Die Stamping Additionally, the pipe number shall be placed by cold rolling or tow stress dot marking on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In case of non-availability of either cold rolling or low stress dot marking facility in pipe mill, an alternative marking scheme of a permanent nature may be proposed by the Manufacturer. 1.3.4 Specified Dimensions:

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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phases of the production of pipes. The manufacturing procedure shall as a minimum include the following information. - Steel/Plate/skelp maker and plant at which steel is produced. - Steel making process with details of secondary refining process and continuous casting process, nominal weight of each heat. - Target chemistry, range of intentionally added elements, limits on heat and product analysis to be placed on steel maker. - Plate/skelp rolling procedure indicating number of passes, their temperature and thickness reduction in each pass required by Controlled Rolling Procedure and the finishing temperature. - Heat treatment procedure document established as per para 5.4. - Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details of equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard for calibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling, inspection and recording. - Pipe making procedure including plate edge preparation, forming and any other special process proposed. - Welding procedure specification including the details of welding process, brand name, classification, size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of each electrode, welding current and voltage for each wire, edge preparation, tack welding method and spacing of tack weld, details of seam tracking system for both inside and outside welding, method of checking the setup of the system, limits of internal and external weld reinforcement etc.
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In addition to the WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill. Establishing the WPS of pipe mill doesnt absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. - Method of weld defect removal. - Detailed methodology of cold expansion. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.

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ANNEXURK -II(NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. These first day's production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In addition ,change of width of coil shall also call for first day production tests. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated against the corresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from the radiograph, a cross section of the weld, at the location of the abovementioned ultrasonic indication shall be made in such a way that the nature of the imperfection can definitely be established. c. Radiographic Examination The weld seam of all pipes shall be examined radiographically for the entire length. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed.
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The following tests shall be conducted: i. Four (4) weld guided bend test specimen transverse to the longitudinal weld shall be removed. Of the four specimens, two specimens shall be used for the face bend test and two for the root bend test. ii. Tensile tests shall be conducted on: Two (2) transverse base material specimens. Two (2) transverse weld material specimen of the longitudinal weld. Two (2) cylindrical all-weld specimen of the longitudinal weld.

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

The base metal specimen shall be tested at - 40, -10, 0, + 20 C for shear area and absorbed energy to produce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification for shear area and absorbed energy respectively shall be complied with. For other temperatures, the value shall be for information only. The sets of weld and HAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as per SR 19 of API Spec. 5L. v. At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in a transverse direction. The sets of 3 base metal specimen shall be tested at -40, 10, 0, +20C for shear area to produce full transition curve. The value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only. (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi. Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. e. In addition, all the tests and inspections require to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test. f. In case of any test failure, no re-testing shall be applied and the entire first day production shall be rejected.

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ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING The following information as applicable shall be furnished at Bid stage with respect to line pipe to be supplied. - Name(s) of proposed Manufacturer(s) - Authorization letter(s) from Manufacturer(s) where applicable. - Authorization letter(s) from Manufacturer(s) of steel plates, in case plate manufacturing facility is not an integral part of the Suppliers pipe mill. - Record of similar supplies made earlier by the Manufacturer for both plates and pipes, giving complete details of diameter, thickness, length, grade of plate / pipe, service, year, name of project, name of client, and contact person. In particular, details of similar supplies made over the last five years shall be furnished. Descriptive technical catalog(s) of the proposed Manufacturer(s). - Copy of valid certificate of Authority to use API monogram as per clause 1.2 of this specification. - A clause wise list of technical deviations, if any, from the requirements of this specification shall be furnished in the Performa enclosed with the Enquiry. Deviations indicated anywhere else in the offer shall not be considered valid. In case of no deviations, Bidder shall write NO DEVIATIONS in the said performa.

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

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FIGURE: 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

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

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

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

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

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

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Abbreviations: ASTM API ID HSAW HAZ NDT NPS OD WT American Society for Testing and Materials American Petroleum Institute Inside Diameter Helical Seam Submerged Arc Welded Heat Affected Zone Non Destructive Testing Nominal Pipe Size Outside Diameter, Specified Wall Thickness, Specified

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

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CONTENTS 1 2 5 6 7 9 10 11 12 14 APPENDIX-B APPENDIX-C APPENDIX-F SR 5 SR 6 SR 7 PSL 2 PIPE APPENDIX-H APPENDIX-I SCOPE REFERENCES PROCESS OF MANUFACTURE AND MATERIAL MATERIAL REQUIREMENTS DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES INSPECTION AND TESTING MARKING COATING AND PROTECTION DOCUMENTS (New) INSPECTIONS OF FIELD TESTS & WARRANTY REPAIR OF DEFECTS BY WELDING (NORMATIVE) REPAIR WELDING PROCEDUR (NORMATIVE) SUPPLEMENTARY REQUIREMENTS (NORMATIVE) FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4 OR LARGER DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER. ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PURCHASER INSPECTION (NORMATIVE) MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)
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ANNEXURE-I ANNEXURE-II FIGURE 6.2.6.1 FIGURE 6.2.6.2 FIGURE 7.8.3 FIGURE9.8.5.2 SEAM

MANUFACTURING PROCEDURE SPECIFICATION FIRST DAY PRODUCTION TESTS (New) METALLOGRAPHIC SPECIMEN EXTRACTION PLAN LOCATIONS FOR HARDNESS MEASUREMENT PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD

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1. 1.1

SCOPE PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of helical (spiral) seam submerged arc welded steel line pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and makes restrictive amendments to API Spec. 5L. Unless modified and or deleted by this specification, the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering that of API Spec 5L in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of API Spec. 5L, Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2.

1.2 2. 1.3

PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL GRADE This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4

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

2.0 2.1

References The latest edition (edition enforce at the time of issue of enquiry) of following additional references are included in this specification: ASTM E 92 ASTM R 112 BS 5996
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: : :

Test Method for Vickers Hardness of Metallic Materials. Standard Test Methods for Determining Average Grain Size. Specification for the Acceptance Level for Internal

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Imperfection in Steel Plate, Strip and Wide Flats, based on Ultrasonic Testing. ASME IX ASME B31.8 OISD 141 API RP 5 L1 5 : : : : Boiler & Pressure Vessel code: Welding & brazing quality. Gas Transmission & Distribution piping system. Oil Industries safety distribution piping system Recommended practice for railroad transmission of line pip

Process of Manufacture and Material

Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process Type of Pipe Type of Seam Weld : Submerged Arc Welding as per para 5.1.2.2.1 : Helical Seam Submerged Arc Welded Pipe as per para 5. 1.3.11 : Submerged Arc Weld (Helical Seam) as per para 5.1.4.3

A manufacturing procedure specification (MPS) as described in Annexure-I of this specification shall be prepared and submitted to purchaser for approval prior to start of production. 5.1.2.2.1 Submerged Arc Welding Process The submerged arc welding equipment shall have an automatic weld tracking system capable of ensuring accurate positioning of welding head and the welding edges of the skelp. 5.2 COLD EXPANSION Pipes furnished to this specification shall be non-expanded. 5.3 5.3.3 MATERIAL (New)
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Line pipe furnished to this specification shall be made from steel produced in basic oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM B 112. Steel shall be made by continuous casting only. 5.4 HEAT TREATMENT The pipes shall be produced from skelp which shall be quenched and tempered or controlled rolled or combined controlled rolled and accelerated cooled to impart uniformly fine ferritic grain structure to the finished steel. Other types of heat treatment shall be agreed upon between Purchaser and Manufacturer. 5.5 SKELP END WELDS IN HELICAL SEAM PIPE Junctions of skelp end weld and helical seam welds in finished pipe are not permitted. 6 6.1 6.1.1 Material Requirements CHEMICAL PROPERTIES Chemical Composition The chemical composition of each heat of steel on product analysis shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element C Mn Product Analysis (percent by weight) 0.16 1.50 1.60 Si 0.15 0.45 S P Al
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max max. (For Grade B to X52) max (For Grade X56 to X70) min max max max max
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0.015 0.02 0.07

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

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Nb V Ti

0.05 0.08 0.04 0.06

max. max. max. (For Grade B to X60)

max. (For Grade X65 to X70) max. max. max max max max

Cr Mo Cu Ni N B Note: g (New)

0.20 0.10 0.35 0.20 0.012 0.0005

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

If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 6.1.2 Elements Analysed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analyzed and reported, even if those are not purposely added but are present as residuals only. 6.1.3 Carbon Equivalent (PSL 2 Only)
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6.1.3.1 Calculation of Carbon Equivalent Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%. 6.1.3.2 Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits: CE (Pcm) CE (IIW) 6.2 6.2.1 0.20 0.40

MECHANICAL PROPERTIES Tensile Properties The finished pipe shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5 L Grade Up to and including X46 X52 to X65 X70 and above Permissible in excess of SMYS. psi (MPa) 19,000 (131) 22,000(152) 20,000(138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90, when tested using flattened tensile specimen. The ratio between yield strength and ultimate tensile strength for weld metal of finished pipe shall not exceed 0.90, when tested using cylindrical all weld specimen. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the formula given in foot note (a) of Table-3B and shall comply with the minimum values of API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API Spec 5L Appendix D stands modified accordingly.
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6.2.5 6.2.5.2

Fracture Toughness Tests Charpy Impact Tests for PSL 2

f. (New) For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. 6.2.5.3 Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area, in accordance with Supplementary Requirement SR 5A of API' Spec 5L and as modified in this specification shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order, Drop Weight Tear Test in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all pipe size, grade and wall thickness. 6.2.6 Metallographic Examination

6.2.6.1(New) A test specimen for metallographic & hardness examination shall be taken transverse to the helical weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) whichever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen extraction shall be as per Fig. 6.2.6.1 of this specification. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that proper fusion has been obtained for the full thickness, and there is proper interpretation of passes, their alignment and texture of weld zone. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's Representative. 6.2.6.2(New) Vickers hardness tests shall be carried out on each specimen taken for metallographic examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this specification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected Zone shall start as close to the fusion line as possible. The resulting Vickers hardness
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value at any point shall not exceed 248 HV10. Modalities of retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7 Residual Stress Test (New) Helical pipes shall meet the testing and minimum acceptance criteria set forth in this paragraph. The residual stress test shall be carried out on the pipe after hydrostatic test. 6.2.7.1 Testing Frequency (New) One test shall be carried out at the beginning of each shift. Minimum of one test shall be carried out for pipes of each grade, size and specified wall thickness. In addition, whenever the production line settings are changed, the first produced pipe shall be tested for residual stress. 6.2.7.2 Test Specimen (New) The teat specimen shall be 150mm wide ring cut from one end of the pipe. The specimen shall either be cut using flame cutting torch or by sawing from the parent pipe. 6.2.7.3 Testing (New) The specimen ring shall be severed by flame cutting or sawing parallel to the longitudinal axis of the pipe. The cut shall be 180 degree from the spiral weld. (Specimen ring shall be allowed to cool down to ambient temperature prior to cutting) 6.2.7.4 Computation of Residual Stress (New) The increase in circumference, if any, after severing shall be measured using fiducial marks of known separation on the specimen prior to severing. The residual stress then shall be calculated using following formula. S = {(E*t*C)/(12.556 *R2)}-{(F*R2)/t} Where: S C t E Residual Stress, kPa (psi) Increase in circumference, mm (in) Specified wall thickness, mm (in) Young's Modulus of Elasticity, 2 x 108kPa, (29 x 106psi)
SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE) DOCUMENT No. S-04-02-002 REV-0 Page 11 of 43

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R F 6.2.7.5

Pipe Radius, mm (0.5 * Specified outside diameter), mm (in) 0.1154 in SI units, (0.425 in conventional units)

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

6.2.7.6

Retests (New) If any specimen fails to meet the requirements of paragraph 6.2.7.5 above, the pipe may be retested once. The retest specimen shall be obtained from the same end of the pipe from where the failed specimen was obtained. If the results obtained from the retest specimen are acceptable, normal test schedule shall be resumed. If the results obtained from retest specimen are not acceptable, the pipe shall be rejected and testing shall resume on the next pipe in the production line. If this test also fails all pipes back to the last acceptable test shall be individually tested and those pipes which pass the test shall be accepted. All pipes that fail to pass the test shall be rejected. The manufacturer shall evaluate the reasons for the failure of the test and rectify the same prior to start of production again. The regular production shall be resumed only after acceptable test result is achieved.

6.2.7.7 Reporting (New) All residual stress result shall be recorded as part of the mill report. 7 7.2 Dimensions, Weights, Lengths, Defects and End Finishes DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6C, Appendix E. API Spec 5L, Table 7 stands modified accordingly. Size 18 > 20 and <36 >36
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Tolerance 3mm + 3 mm, - 0.25% of specified OD 3mm.


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Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table 8 shall be applicable on the inside diameter. The inside diameter, based on circumferential measurement over a length of 100 mm from the end shall comply with the tolerances specified in API Spec 5L. Inside diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum inside diameter at pipe ends shall not exceed the following: Size 36 >36 Tolerance : : 0.5% of OD <5 mm

Out of roundness tolerance indicated in API Spec 5L, Table 8 stands deleted. Out of roundness tolerances apply to maximum and minimum diameters as measured with a bar gauge, caliper or device measuring actual maximum and minimum diameter. Each pipe shall be measured for conformance to above requirements. All dimensions and tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). 7.4 WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 oclock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wall thickness shall be (+) 15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.5 LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with
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length between 10.0mand 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0 m. API Spec 5L Table 11 shall not be applicable. Overall length tolerance shall be (-) Zero and (+) One pipe length to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurements shall be recorded. 7.6 STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.7 JOINTERS Jointers on pipes are not permitted. 7.8 7.8.1 WORKMANSHIP AND DEFECTS Dents Allowable dent size shall be as per API Spec 5L. Disposition of dents shall be carried out in accordance with API Spec 5L para 9.9 (c) or (d). Dents on weld and heat affected zone (HAZ) are not acceptable. 7.8.2 Offset of Plate Edges Forming and welding operations shall be conducted to minimize coil edge offset and distortion and peaking at the helical or spiral seams. The manufacturer shall provide the appropriate tooling with 'Vee blocks and calibrated dial indicators needed to measure the distortion and misalignment at the seam. All pipes shall be checked for offset of skelp edges. Offset shall be measured and recorded at least 3 times per operating shift (12 hours maximum). Measurements shall be taken at two locations (at a distance of one to two diameters from each end) on each pipe joint. In case of unacceptable offsets, the manufacturer shall adjust the forming and welding equipment. 7.8.3 Out-of-Line Weld Bead for Pipe with Filler Metal Welds A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment shall be measured on radiographic film and calculated using the formula (a+b)/2 where a and b' are the relative offsets of the outside edges of the seam (refer Figure 7.8.3 of this specification). All pipes shall be checked for out-of-line weld bead and shall be
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measured and recorded at least 3 times per operating shift (12 hours maximum). Checking of the weld seam misalignment shall also be carried out on metallographic examination specimen as stated at para 6.2.6. 7.8.4 Height of Outside and Inside Weld Beads - Submerged Arc Welds The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height using a template having a cut out for weld bead and shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.8.8 Hard Spots Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot shall be removed as a cylinder. 7.8.9 Cracks, Sweats and Leaks :

Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the requirement of API Spec 5L para 9.9 (c) or (d). 7.8.10 Laminations Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of defects on the skelp shall be as per para 9.8.5.4 of this specification. 7.8.12 Undercuts Undercutting not classified as minor shall be considered a defect. Disposition shall be as follows: 1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12% of the specified wall thickness shall be removed by grinding in accordance with API Spec 5L para 9.9 (a) and as modified in this specification. 2. Disposition of undercuts greater in depth than 1/32 in. (0.8 mm) or 12% of the specified wall thickness shall be in accordance with API Spec 5L para 9.9 (c) or (d). 7.8.14 Other Defects
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Any imperfection (measured from the surface) with a depth greater than 5% of the specified wall thickness of the pipe shall be considered a defect and shall be repaired in accordance with para 9.9 and as modified in this specification. 7.8.15 Peaking (New) Deviation from the circular arc at the weld seam at pipe ends shall not exceed 1.6 mm. Each pipe shall be checked for conformance to above requirement. Peaking shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum). Pipes not complying to these requirements shall be disposed off as per API Spec. 5L para 9.9 (c) or (d). 7.9 7.9.1 PIPE ENDS General Pipes shall be furnished with plain ends. 7.9.3 Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L. In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metal and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall be rebevelled and rectification by filing or grinding shall not be done. 7.9.6 Bevel Protectors (New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they can be re-used by coating applicator for providing on externally anticorrosion coated pipes subsequent to coating of line pipe. 9 9.2 9.2.1 Inspections and Testing TESTING OF CHEMICAL COMPOSITION Heat Analysis Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be reported by the Manufacturer prior to start of pipe production. 9.2.2 Product Analysis
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9.2.2.1

Sampling Frequency Two pipes per inspection lot shall be analysed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat are also represented.

9.2.2.2

Sampling Method

9.2.2.2 2 Welded Pipe Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from skelp may be used provided the traceability of samples is guaranteed. 9.3 9.3.1 TESTING OF MECHANICAL PROPERTIES Tensile Tests Tensile properties shall be determined from specimen removed from pipe which has been subjected to all mechanical and heat treatment operations. 9.3.1.2 Tensile Testing Frequency Tensile tests shall be made at the frequency of one test per inspection lot as shown in Table 13, except as modified below: Table 13 : Maximum Inspection Lot Size for Tensile Testing For Size >12, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13 shall also be applicable. 9.3.1.4 Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen. 9.3.1.5 Weld Tensile Tests Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. A cylindrical all weld tensile test shall be carried out at the time of first day production test as specified in Annexure-II of this specification to determine the yield strength, ultimate tensile strength and elongation.
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The cylindrical all weld specimen shall have gauge length, L = 5d, where; L = gauge length (mm) diameter of the test specimen (mm)

D =

The results of the teat shall meet the minimum requirements of the skelp with regard to yield, tensile and elongation. As an alternate all weld metal tensile test can be carried out at the time of first day production on the test sample as per ASME Sec.II C. This test shall be repeated in case any change in batch of wire-flux combination, 9.3.5 9.3.5.1 Fracture Toughness Tests Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with heat affected zone (HAZ) in the middle shall also be taken. 9.3.5.2 Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimens each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. 9.4 9.4.1 HYDROSTATIC TESTS Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for each pipe of all sizes and grades. 9.4.2 Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and records shall be maintained. 9.4.3 Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5L para 9.4.3 (Note 2).
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9.4.5 (New)

Burst Test Burst test shall be done on each type of pipe for each size on lowest thickness. Burst pressure & location of failure shall be recorded. Technical audit shall be carried out by OWNER / OWNERS representative during manufacturing. Minimum Burst Test pressure shall not be less than the actual tensile stress factor computed pressure.

9.5

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

9.7

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

9.8

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

9.8.1

Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TCMA or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser.
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Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below: (i)

For UT - For UT, at least one level III qualified inspector shall be available to the mill for overall supervision. A level II inspector is required for shift supervision, manual weld inspection and calibration of all systems (both manual and automated). For alt other NDT methods
Evaluation of indications Supervision : : Level I, II, III inspector Level II or Level III inspector (in case evaluation is by Level I

(ii)

inspector) 9.8.3 Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of weld seam shall be performed after hydro testing. Skelp Inspection The longitudinal edges of the skelp shall be 100% ultrasonically inspected over width of at least 25 mm from the trimmed skelp edge. Remaining skelp shall be ultrasonically tested for laminations using an oscillating or straight running pattern of probes, so as to provide inspection coverage of at least 20% of the skelp surface uniformly spread over the area. Alternatively, skelp UT inspection can be performed after pipe forming provided all applicable requirements as specified above are complied with. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Ends Inspection The full circumference of both ends of each pipe after bevelling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. In addition, full circumference of both ends of each pipe shall be 100 % ultrasonically tested over a circumferential width of at least 50 mm with angular probes to detect cracks, in case of non-availability of angular probes at the mill, the full circumference of both ends of each pipe shall be inspected with magnetic particle
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technique over a circumferential width of at least 50 mm to detect surface cracks. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table-24) using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. Locations showing indications above the allowable limits during ultrasonic inspection shall be re-examined by radiography, if during production, repeated ultrasonic indications occur requiring re-inspection by radiography and it appears from radiographs that the nature of defects causing the ultrasonic indications cannot be definitely established, the Manufacturer shall prove by other inspection methods (e.g. by making some cross-sections in accordance with para 6.2.6 of this specification at locations where such indications occur near the end of the pipe) to the satisfaction of Purchaser that these are not injurious defects as stipulated in this specification. 9.8.3.1 Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. Submerged-arc weld seam shall be radio graphically examined for a minimum distance of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be recorded. 9.8.4 9.8.4.1 Radiological Inspection-Weld Seams Radiological Inspection Equipment The homogeneity of weld seams examined by radiological methods shall be determined by means of X-rays directed through the weld material in order to create a suitable image on radiographic film. The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table-2 of ASTM E 94; with minimum density greater than 1.8 measured in connection with radiographic image of the welding and shall be suitable to allow a sensitivity of at least 1.8 percent of nominal wall thickness.
SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE)

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9.8.4.2

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

9.8.4.8

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

9.8.5 9.8.5.1

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

9.8.5.2

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

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

9.8.5.4.1 Skelp Edges (New) Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4. Disposition of any defect shall be as per API Spec L, para 9.9 (c) or (d). 9.8.5.4.2 Remaining Skelp (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference:
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1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width : 8 mm. (The length is the dimension at right angles to the scan track and the width is the dimension parallel to the scan track) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the skelp surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7 Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gauss meter. All residual magnetism measurements shall be recorded. 9.9 DISPOSITION OF PIPE CONTAINING DEFECTS a. Suitable tools to eliminate defects by grinding shall be used. The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with API Spec 5L para 9.9 (c) or (d). b. Repair welding on parent metal is not permitted. c. In addition to NTD requirement random radiography of 0.1% of the total length shall be done. The areas to be radiographed shall be at the sole discretion of Third Party Inspection Agency. 9.10 9.10.3 TEST METHODS Guided-bend Test One face and one root guided bend weld test shall be made on samples cut from pipe. The frequency of testing shall be same as for tensile test as per para 9.3.1.2 of this specification. The dimension A in guided bend test shall not exceed 4.0 times the thickness of the specimen.
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9.10.4 Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification. 9.12 9.12.1 RETESTS Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analyzed to meet the requirements of Table 2B of this specification. 9.12.7 Charpy Retests In the event that a set of Charpy test specimen fails to meet the acceptance criteria, the manufacturer may elect to replace the lot (refer para 9.3.5.2 of this specification) of material involved or alternatively to test two more lengths from that lot. If both the new tests meet the acceptance criteria, then all pipes in that lot, with the exception of the original selected length, shall be considered to meet the requirement. 9.13 REPROCESSING This para stands cancelled. 10 10.1 Marking GENERAL Marking specified in API Paragraphs and otherwise specified in the Purchase Order shall be in English language and international system (SI) of units. Marking shall comply with Appendix-I of API Spec 5L and as modified in this specification.

11 11.1

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

12 12.1

Documents CERTIFICATION
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Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix F Supplementary Requirement SR 15 shall also be submitted to Purchaser/Purchaser Representative during inspection at pipe mill. 12.2 RETENTION OF RECORDS In addition to the records indicated in API Spec 5L Table 27, the Manufacturer shall retain the records of all additional tests and calibration records mentioned in this specification including the hard copy records of ultrasonic testing carried out on pipe/skelp as well as pipe ends. 12.3 PRODUCTION REPORT (New) The Manufacturer shall provide six copies of production report in English language indicating at least the following for each pipe. International system of units (SI) shall be adopted. - Pipe number - Heat number from which pipe is produced - Pipe length and weight. - Pipe grade The Manufacturer shall provide six copies of acceptance certificates which shall include the results of all tests required as per this specification and performed on delivered material giving details of, but not limited to, the following: - All test certificates as per SR 15.1. - Records of qualification of welders and procedures for repair welding. - Certified reports of dimensional, workmanship and defects inspection. - Data on test failures, rejected heats/lots, etc. - Alt other reports and results required as per this specification. The certificates shall be valid only when signed by the Purchaser's Representative. Only those pipes, which have been certified by the Purchaser's Representative, shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order the production report may consist of only test certificates required as per SR 15 of API Spec
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5L and other test reports/results required as per this specification. 12.4 (New) The line pipe data shall be provided in MS EXCEL/MS ACCESS format in compact Disc (CD). The specific data to be recorded shall be agreed between Purchaser and the Manufacturer and shall include, but not limited to, the following: - All marking information - Data of skelp and pipe manufacture - All mechanical properties from test results - All dimensional records - All workmanship and defects inspection records - Final inspection and release date - Description and disposition of repairs - Load-out /dispatch date - Destination - Consignment details. 14 Inspection of Field Tests & Warranty (New) Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not be postponed because of absence of the Manufacturer's Representative. LINE PIPE TRACEABILITY DATA

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APPENDIX B REPAIR OF DEFECTS BY WELDING (NORMATIVE) B.1.2 B.I.2.1 B.3 B 3.1 B.3.2 Weld Seam of Welded Pipe Repaired welds shall be inspected both by X-ray and UT. Procedure for Repair of Submerged-Arc and Gas Metal-Arc Welds The defective part of the weld shall be clearly marked on the pipe so that the defect can be easily located and repaired. Following requirements shall also be complied with for repair welding: a. b. c. d. e. f. B.3.4 (New) The Manufacturer shall also maintain a record of repairs carried out. The records shall include repair number, pipe identification number, welding procedure applicable and NDT details. No repair of weld seam is permissible alter hydrostatic testing. No repair of weld seam is permissible at pipe ends up to a length of 300 mm. Cumulative length of weld seam repairs on one pipe length shall not exceed 10% of the length of pipe. Maximum two repair per pipe are allowed. Repair welding shall be executed only Purchaser Representative for each repair. No repair of a repaired weld is permitted. The repair weld shall be performed with a minimum of two passes. after specific approval by

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APPENDIX-C REPAIR WELDING PROCEDURE (NORMATIVE) C.2 C.2.2 Repair Welding Procedure Qualification Mechanical Testing

C.2.2.3 Transverse Guided-Bend Test The radius of male member of the jig used for guided bend tests shall be RA =2.25 t, where t is specified wall thickness of pipe. C.2.2.5 (New) For all pipes where fracture toughness test is specified, Charpy V-Notch impact test as specified shall be included in the Repair Welding Procedure Qualification. C.2.2.6 (New) Hardness test as specified in para 6.2.6.2 of this specification shall be included in the procedure qualification. The location of the hardness measurements is to be indicated taking into account die new HAZ of the repaired area.

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PPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Larger SR 5.1 SR 5.3 SR 5.4 SR 5.5 SR 5A Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 1/2 or The Manufacturer shall perform Charpy V-notch test for determining Shear Area. The specimen shall be full sized or largest obtainable sub size in case pipeline diameter and thickness does not permit full size specimen Flattened specimen shall not be used. This para stands deleted. Shear Area

SR 5 A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32F (0C), The average shear value of the fracture appearance of the three specimen shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%. The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec 5L SR5A.3, SR 5A.4, SR 5A.5 and SR5A.6 shall be replaced by 'lot'. Lot shall be as per SR5A.1 as above. Drop Weight Tear Testing (DWTT) on Welded Pipe When required as per para 6.2.5.3 of this specification, fracture toughness for all pipe size, grades and specified wall thickness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer in accordance with the requirements of SR 6.2 thru SR 6.8 of API Spec 5L and as modified in this specification. Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. Unless specified otherwise, the test shall be conducted at +32F (0C). At least 80% of the heats shall exhibit a fracture appearance shear area of 75% or more for the specified test temperature.
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Note:

SR 6 SR6.1

SR 6.2

SR 6.4

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Note:

Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by 'lot'. Lot shall be as per SR6.2 as above. Additional Fracture Toughness Requirements (Transverse Charpy VNotch) for PSL 2 Pipe Except as allowed by SR 19.2 of API Spec 5L, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and as modified in this specification, with a test temperature of 32F (0C) or at a lower temperature as specified in the Purchase Order. The required minimum all-heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19 (a) of API Spec 5L and SR 19.1(b). In case longitudinal specimen is applicable as per Table 14 of API Spec. 5L, the minimum average absorbed energy value shall be 13 times that applicable for transverse specimen. The required minimum average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1(a) and SR 19.1 (b) of API Spec 5L, In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.

SR19 SR 19.1

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APPENDIX- H PURCHASER INSPECTION (NORMATIVE) H.4 Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.

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APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.0 1.1 1.2 General Marking shall also include Purchase Order number/item number, pipe number, heat number and weight. Location of Markings Paint used for stencil marking shall withstand a temperature up to 250C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator. 1.3 1.3.4 Sequence of Marking Specified Dimensions: Actual pipe weight in kg shall also be marked. 1.3.5 Grades and Class: A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of ISO mm from the pipe ends. 1.5 Length Actual length shall be marked in metres. 1.7 Die Stamping Additionally, the pipe number shall be placed by cold rolling or low stress dot marking on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In case of non-availability of either cold rolling or low stress dot marking facility in pipe mill, an alternative marking scheme of a permanent nature may be proposed by the Manufacturer.

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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phases of the production of pipes. The manufacturing procedure shall as a minimum include the following information. - Steel/Plate/skelp maker and plant at which steel is produced. - Steel making process with details of secondary refining process and continuous casting process, nominal weight of each heat. - Target chemistry, range of intentionally added elements, limits on heat and product analysis to be placed on steel maker. - Skelp rolling procedure indicating number of passes, their temperature and thickness reduction in each pass required by Controlled Rolling Procedure and the finishing temperature. - Heat treatment procedure document established as per para 5.4. - Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details of equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard for calibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling, inspection and recording. - Pipe making procedure including skelp edge preparation, forming and any other special process proposed. - Welding procedure specification including the details of welding process, brand name, classification, size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of each electrode, welding current and voltage for each wire, edge preparation, tack welding method and spacing of tack weld, details of seam tracking system for both inside and outside welding, method of checking the setup of the system, limits of internal and external weld reinforcement etc. In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the
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pipe mill. Establishing the WPS of pipe mill doesnt absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site. - Method of weld defect removal. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.

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

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ANNEXURE -II (NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. These first days production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In addition, change of width of coil shall also call for first day production test. The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes- in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall be examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated against the corresponding points on the radiographs. If the ultrasonic indication cannot be fully explained from the radiograph, a cross section of the weld, at the location of the above-mentioned ultrasonic indication shall be made in such a way that the nature of the imperfection can definitely be established.
GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR HELICAL (SPIRAL) SEAM SUBMERGED ARC WELDING (HSAW) LINE PIPE (ONSHORE) DOCUMENT No. S-04-02-002 REV-0 Page 36 of 43

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c. Radiographic Examination The weld seam of all pipes shall be examined radio graphically for the entire length. d. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed. The following tests shall be conducted: i.Four (4) weld guided bend test specimen transverse to the helical weld shall be removed. Of the four specimen, two specimen shall be used for the tact- bend test and two for the root bend test. ii.Tensile tests shall be conducted on: - Two (2) transverse base material specimen. - Two (2) transverse weld material specimen of the helical weld. - Two (2) cylindrical all-weld specimen of the helical weld. iii.Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be taken for metallographic examination. Two of these shall be tested for hardness at room temperature after etching. iv.Fracture toughness testing specimen shall be extracted as follows: Four sets of three transverse specimen each from base metal One set of 3 transverse specimen with weld in middle One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 20 C for shear area and absorbed energy to produce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification for shear area and absorbed energy respectively shall be complied with. For other temperatures, the value shall be for information only. The sets of weld and HAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as per SR 19 of API Spec. 5L. v.At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in a transverse direction. The sets of 3 base metal specimen shall be tested at -40, -10, 0, +20C for shear area to produce full transition curve. The
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value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only. (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi.Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. vii. One specimen from one pipe end shall be taken for residual stress test. e. In addition, all the tests and inspections require to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test. f. In case of any test failure, no re-testing shall be applied and the entire first day production shall be rejected.

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

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ANNEXURE III (NEW) INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING The following information as applicable shall be furnished at Bid stage with respect to line pipe to be supplied. Name(s) of proposed Manufacturer(s) Authorisation letter(s) from Manufacturer(s) where applicable. Authorisation letter(s) from Manufacturer(s) of skelp, in case skelp manufacturing facility is not an integral part of the Suppliers pipe mill. Record of similar supplies made earlier by the Manufacturer for both skelp and pipes, giving complete details of diameter, thickness, length, grade of skelp / pipe, service, year, name of project, name of client, and contact person. In particular, details of similar supplies made over the last five years shall be furnished. Histogram for dimensional parameter, chemical analysis and tensile test indicating minimum, maximum, average and standard deviation for the previous supplies. Descriptive technical catalog(s) of the proposed Manufacturer(s). Copy of valid certificate of Authority to use API monogram as per clause 1.2 of this specification. A clause wise list of technical deviations, if any, from the requirements of this specification shall be furnished in the Performa enclosed with the Enquiry. Deviations indicated anywhere else in the offer shall not be considered valid. In case of no deviations, Bidder shall write NO DEVIATIONS in the said Performa.

GAIL (INDIA) LTD NEW DELHI

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

DOCUMENT No. S-04-02-002

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FIGURE : 6.2.6.1 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

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

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GAIL (INDIA) LTD NEW DELHI

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

DOCUMENT No. S-04-02-002

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

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

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

DOCUMENT No. S-04-02-002

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SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

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STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

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CONTENTS S.No. 1 2 3 4 5 6 7 Description INTENT OF SPECIFICATION SCOPE OF WORK COVERAGE REFERENCES MANUFACTURING PROCESS INSPECTION & TESTING MARKING & DESPATCH Page No. 2 2 2 2 2 3 3

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STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

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1.0 1.1

INTENT OF SPECIFICATION This specification establishes the minimum requirements for the manufacture of Seamless Pipes in accordance with the requirements of API (American Petroleum Institute) Specification 5L- 2000 (Forty Second Edition). Unless modified and referred by this specification the requirements of API Spec. 5L2000 shall be valid. SCOPE OF WORK The scope of the tenderer includes manufacture / supply, inspection / testing , marking & packaging and despatch of seamless linepipes as indicated in the Material Requisition (MR). All codes and standards for manufacture, testing, inspection, etc, shall be of latest edition. Purchaser also reserves the right to delete or order additional quantities during execution of order, based on unit rates and other terms & conditions in the original order. COVERAGE The coverage by this specification is limited to linepipe covering non-sour hydrocarbons in liquid or gaseous phase in accordance with API Specification 5L - 2000 (PSL-1 and PSL-2 requirements, as applicable) covering seamless line pipes of sizes and grades as indicated in the MR. REFERENCES All pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydrotest and other testing and marking requirements shall Conform to the latest codes and standards specified in the MR. Deviations, if any, shall be clearly highlighted in the offer. The latest edition of following additional references are included in this Specification: ASTM ASTM E 92: Test Method for Vickers Hardness of Metallic Materials
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1.2

2.0 2.1

2.2 2.3

3.0 3.1

4.0 4.1

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ASTM E 112: Standard Test Methods for Determining Average Grain Size. BS BS 5996: Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats based on Ultrasonic Testing 5.0 5.1 5.2 5.3 6.0 6.1 MANUFACIURING PROCESS Steel made by acid Bessemer process shall not be acceptable. Pipes shall be supplied in double random length, i.e. pipe length between 11.5 m and 12.5 m with an average length of 12.0 m. Seamless pipes shall not have any circumferential seam joint in a random length. INSPECTION & TESTING All pipes shall be hydrostatically tested. The test mill pressure shall be as follows: GROUP 1 (SEAMLESS,ERW & SPIRAL WELDED) A CARBON STEEL MATERIAL STD ASTM A106 GR.B API 5L GR.B,SEAMLESS API 5L,E.R.W API 5L,SPIRAL ASTM A333 GR.3 & 6,SEAMLESS ASTM A333 GR.3 & 6,E.R.W : : : : : : :

S No.
(i) (ii) (iii) (iv) (v) (vi) B

TEST PRESSURE
ASTM A 530 API 5L API 5L API 5L ASTM A530 ASTM A530

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

S No.
(i) (ii)

:
A335 : :

TEST PRESSURE
ASTM A530 ASTM A530

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STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

DOCUMENT No. S-04-02-003

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SEAMLESS STAINLESS STEEL

S No.
(i) D

MATERIAL STD ASTM A312 GR. TP304 ,304L ,304H, 316, 316L, 316H, 321, 347
SEAMLESS NICKEL ALLOY MATERIAL STD ASTM B161 UNS ASTM B165 UNS ASTM A167 UNS ASTM A407 UNS

:
:

TEST PRESSURE
ASTM A530

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

:
NO2200 NO4400 NO6600 NO8800 : : : :

TEST PRESSURE
ASTM B161 ASTM B165 ASTM B167 ASTM B407

6.2 6.3

Material test certificates (physical properties, chemical composition & heat treatment report) shall also be furnished for the pipes required. Pipe with bevelled ends shall be in accordance with ASME B16.25. Weld contour shall be as per Figure-2, Type-A. MARKING & DESPATCH

7.0

7.1

All pipes shall be marked in accordance with the applicable codes, standards & specifications. Additionally, purchase order number, item code and special conditions, if any, shall also be marked. Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead or copper which cause corrosive attack on heating. Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind. Pipes shall be protected from rust, corrosion & mechanical damage during transportation, shipment and storage. Rust preventive, used on machined surfaces to be welded, shall be easily removable with a petroleum solvent and the same shall not be harmful to welding.
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7.2 7.3 7.4 7.5

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STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

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7.6 7.7

Both ends of pipes (Bevelled Ends) shall be protected with wood, metal or plastic cover. End protectors to be used on bevelled ends shall be securely and tightly attached with belt or wire.

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STADARD SPECIFICATION FOR SEAMLESS LINE PIPE (ONSHORE)

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

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

DOCUMENT No. S-04-02-004

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CONTENTS 1 2 5 6 7 9 10 11 12 14 APPENDIX-F SR 5 SR 6 SR 17 SR 19 SCOPE REFERENCES PROCESS OF MANUFACTURE AND MATERIAL MATERIAL REQUIREMENTS DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES INSPECTION AND TESTING MARKING COATING AND PROTECTION DOCUMENTS (New) INSPECTIONS OF FIELD TESTS & WARRANTY SUPPLEMENTARY REQUIREMENTS (NORMATIVE) FRACTURE TOUCHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF SIZE 4 OR LARGER DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER, GRADE X52 OR HIGHER PIPE AND LASER NON DESTRUCTIVE INSPECTION OF WELDS IN ELECTRIC WELDED PIPE AND LASER WELDED PIPE ADDITIONAL FRACTURE TOUGHNESS REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE PURCHASER INSPECTION (NORMATIVE) MARKING INSTRUCTIONS FOR API LICENSEE (NORMATIVE) MANUFACTURING PROCIDURE (New) ANNEXURE-II FIRST DAY PRODUCTION TESTS (New) FIGURE 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT FIGURE 6.2.7 REVERSE BEND TEST FIGURE 9.8.5.2 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM

APPENDIX-H APPENDIX-I ANNEXURE-I

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

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Abbreviations: ASTM API ID EW HAZ NDT NPS OD WT American Society for Testing and Materials American Petroleum Institute Inside Diameter Electric Welded Heat Affected Zone Non Destructive Testing Nominal Pipe Size Outside Diameter, Specified Wall Thickness, Specified

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

DOCUMENT No. S-04-02-004

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1. Scope 1.1 PURPOSE AND COVERAGE This specification establishes the minimum requirements for the manufacture of longitudinal seam electric welded steel tine pipe in accordance with the requirements of API (American Petroleum Institute) Specification 5L Forty-Third Edition, 2004 and makes restrictive amendments to API Spec. 5L. Unless modified and or deleted by this specification, the requirements of API Spec. 5L shall remain applicable. The sections, paragraphs and appendices contained herein have the same numbering as that of API Spec SL in order to facilitate reference. Additional requirements, which are not specified in API Spec 5L, have also been numbered and marked as "(New)". The coverage by this specification is limited to line pipe to be used in onshore pipelines transporting non-sour hydrocarbons in liquid or gaseous phase. The Manufacturer shall have a valid license to use API Monogram in accordance with the requirements of API Spec 5L Forty-Third Edition, 2004 on line pipe as Product Specification Level PSL 2. 1.2 PRODUCT SPECIFICATION LEVEL (PSL) Line pipe supplied to this specification shall conform to Product Specification Level PSL 2. 1.3 1.4 GRADES This specification is applicable to PSL 2 line pipes of grade B through X70. DIMENSIONS This specification shall be applied to line pipe of size 4 1/2 through 20 (both sizes included), 2. 2.1 References The latest editions (edition enforce at the time of issue of enquiry) of following additional references are included in this specification: ASTM ASTM E 92 : Test Method for Vickers Hardness of Metallic Materials. ASTM E 112 : Standard Test Methods for Determining Average Grain Size. BS BS 5996 : Specification for the Acceptance Level for Internal Imperfection in Steel Plate, Strip and Wide Flats, based on Ultrasonic Testing.
SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE) DOCUMENT No. S-04-02-004 REV-0 Page 4 of 34

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OISD 141 ASME IX ASME B31.8 API RP 5 L 5 5.1

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

Process of Manufacture and Material PROCESS OF MANUFACTURE Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured as per this specification: Welding Process Type of Pipe Type of Seam Weld : : : Electric Welding as per para 5.1.2.1.2. Electric Welded Pipe as per para 5.1.3.3 & 5.1.3.3.2. Electric Weld as per para 5.1 .4.1.

5.1.3.3.2 PSL 2 ELECTRIC WELDED PIPE Electric welding shall be performed with a minimum welder frequency of 200 kHz. The welding system shall have an integrated control in which following data as a minimum shall be monitored: Time Welding speed Current and Voltage Heat treatment temperature

The weld seam and the entire Heat Affected Zone (HAZ) shall be heat treated so as to stimulate a normalizing heat treatment in order to control the structure so that no untempered martensite remain in the weld seam and the HAZ, and the mechanical properties of heat treated zone approximate that of the parent metal. 5.2 5.3 COLD EXPANSION Pipes furnished to this specification shall be non-expanded. MATERIAL Line pipe furnished to this specification shall be made from steel produced in basic oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully killed and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel shall be made by continuous casting only.
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5.3.3 (New)

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5.4

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

6 6.1 6.1.1

Material Requirements CHEMICAL PROPERTIES Chemical Composition The chemical composition of each heat of steel on product analysts shall be in accordance with Table 2B and notes given below. Table 2B of API Spec 5L is cancelled. Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of Weight Element C Mn Si S P Al Nb V Ti Cr Mo Cu Ni N B
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Product Analysis (percent by weight) 0.16 1.50 1.60 0.15 0.45 0.01 0.02 0.07 0.05 0.08 0.04 0.06 0.20 0.10 0.35 0.20 0.012 0.0005 max max (For Grade B to X52) max (For Grade X56 to X70) min max max max max max max max (For Grade B to X60) max (For Grade X65 to X70) max max max max max max
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SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

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Note: i. ii. iii.

g (New)

V+Nb+Ti shall not exceed 0.15%. Cu+Ni shall not exceed 0.40%. Al/N shall be min. 2.

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

DOCUMENT No. S-04-02-004

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Note: h (New) If alloying elements other than those specified in Table 2B above are added to the steel, the limits of the additional components shall be agreed with the Purchaser. Note: i (New) Minimum for Si is not applicable for Al killed steel. 6.1.2 Elements Analyzed For heat analysis and product analysis, all the elements listed in Table 2B of this specification shall be analyzed and reported, even if those are not purposely added but are present as residuals only. 6.1.3 6.1.3.1 Carbon Equivalent (PSL 2 Only) Calculation of Carbon Equivalent Boron content shall be considered in CE (Pcm) formula even if it is less than 0.0005%. 6.1.3.2 Maximum Carbon Equivalent For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the following limits: CE (Pcm) CE (IIW) 6.2 6.2.1 0.20 % 0.40 %

MECHANICAL PROPERTIES Tensile Properties The finished pipe (after all heat treatment and expansion or sizing operations) shall conform to the requirements of Table 3B of API Spec 5L and as modified herein. The actual yield strength shall be as close as possible to the specified minimum yield strength (SMYS) but in no case it shall exceed the limits specified here under: API Spec 5L Grade Up to and including X46 X52 to X56 X70 Permissible in excess of SMYS. psi (MPa) 19,000 (131) 22,000(152) 20,000(138)

The ratio of body yield strength and body ultimate tensile strength of each test pipe on which body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90. The ultimate tensile strength of the weld shall be equal to or better than the specified minimum ultimate tensile strength of the base metal. The minimum elongation of base metal shall be determined in accordance with the
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formula given in the foot note (a) of Table-3B and shall comply with the minimum values of API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API Spec 5L Appendix D stands modified accordingly. 6.2.2 Flattening Test Acceptance Criteria Dye penetrate testing may be used to positively confirm the presence of crack, break or opening. 6.2.5 6.2.5.2 f. (New) Fracture Toughness Tests Charpy Impact Tests for PSL 2 For all pipe sizes and specified wall thickness, additional fracture toughness requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L and as modified in this specification shall be applicable for body, weld and heat affected zone. Supplementary Fracture Toughness Tests For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for determination of Shear Area in accordance with Supplementary Requirement SR 5 A of API Spec 5L and as modified herein shall be performed. In addition, whenever line pipes are specified for hydrocarbon service in gaseous phase and Liquefied Petroleum Gas (LPG) service in Purchase Order for pipe size 16 and larger, Drop Weight Tear Test (DWTT) in accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in this specification shall be also performed for all grades and wall thickness. 6.2.6 Metallographic Examination A test specimen for metallographic & hardness examination shall be taken transverse to the longitudinal weld, from one finished pipe from each lot of 50 pipes per heat or at least once per operating shift (12 hrs maximum) which ever is occurring more frequently and whenever changes of grade, diameter or wall thickness are made and whenever significant excursions from operating heat treatment conditions are encountered. The specimen shall be suitably ground, polished and etched to reveal the macro-structure. The specimen shall be visually examined using a minimum 10X magnification to provide evidence that heat treatment of weld zone is adequate and there is no untempered martensite left. In case imperfections or defects are observed, it will become a cause for re-evaluation of welding parameters and heat treatment as deemed necessary by Purchaser's
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6.2.5.3

6.2.6.1 (New)

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Representative. 6.2.6.2 (New) Vickers hardness tests shall be carried out on each specimen taken for metallographic examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this specification. Indentation in the Heat Affected Zone (HAZ) shall start as close to the fusion line as possible. The resulting Vickers hardness value at any point shall not exceed 248 HV10. The maximum difference in hardness between (the base metal and any reading taken on the weld or heat affected zone shall be less than 80 HV10. Modalities of retest shall be in accordance with para 9.12.2 of API Spec. 5L. 6.2.7 Reverse Bend Test Reverse bend test shall be executed with the some number of tests and retests specified for flattening test in para 9.3.2 of API Spec 5L. Ring Specimen of width 100 mm to 115 mm shall be taken from the pipe and tested in accordance with the procedure given below and Fig. 6.2.7 of this specification. 6.2.7.2 Selection of Mandrel The reverse bend test shall be carried out with a mandrel, whose radius (R), or width (A) shall be calculated for any combination of diameter, wall thickness and grade with the following formula: 6.2.7.1 (New)

Where D t 1.4 e Specified outside diameter of pipe, mm Specified wall thickness of pipe, mm Peaking factor Strain Min e' value 0.1425 0.1375 0.1325 0.1250 0.1125
SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE) DOCUMENT No. S-04-02-004 REV-0 Page 10 of 34

Minimum value of 'e' shall be as follows: Grade of Steel Gr. B X-42 X-46 X-52 X-60
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X-65 X-70 6.2.7.3 (New) Procedure

0.1100 0.1075

The mandrel shall be plunged into the specimen, with the weld in contact with the mandrel, to such a depth that the angle of engagement between mandrel and specimen reaches 60 (Ref. Fig 6.2.7 of this specification). If the combination of diameter and wall thickness of pipe and radius of mandrel is such that the angle of engagement does not reach 60 the mandrel shall be plunged into the specimen until opposite walls of the specimen meet. 6.2.7.4 (New) Acceptance Criteria A specimen which fractures completely prior to the specified engagement of mandrel and specimen, or which reveals cracks or ruptures in the weld or heat affected zone longer than 4 mm, shall be rejected. Cracks less than 6 mm long at the edges of the specimen shall not be cause for rejection. Dye penetrate testing may be used to positively confirm cracks or openings. 7 7.1 Dimensions, Weights, Lengths, Defects and End Finishes DIAMETER Pipe Body The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by more than the values given below from that given in Table E-6B (for size 4 ) and E-6 C (for size 6 5/8 ) Appendix E. API Spec 5L Table 7 stands modified accordingly. Pipe Size >4 1/2 and18 20 Pipe Ends Diameter tolerances for the pipe ends indicated in API Spec 5L Table-8 shall be applicable on the inside diameter for pipe sizes > 14 and on outside diameter for pipe sizes 12. The inside diameter, based on circumferential measurement, over a length of 100
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Tolerance 0.75 % of Specified OD or 3 mm whichever is smaller +3 mm, - 0.25% of Specified OD

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mm from the end shall comply with the tolerances specified in API Spec 5L, Inside diameter is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and specified wall thickness respectively. Out of Roundness Out of Roundness i.e., the difference between the maximum and minimum diameter (inside for pipe size > 14 and outside for pipe size 12) at pipe ends shall comply with the following limits. Pipe size 10 >12 Tolerance 2mm 3 mm

Out of roundness tolerance apply to maximum and minimum diameters as measured with a bar gauge, caliper or device measuring actual maximum and minimum diameter. Out of roundness tolerance indicated in API 5L Table-8 stands deleted. Each pipe shall be measured for conformance to above requirements. All dimensions and tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs maximum). 7.3 WALL THICKNESS In addition to API requirements, the wall thickness of each pipe shall be checked along the circumference at both ends and at the mid location of pipe body at 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall comply with the requirements of this specification. The tolerances on specified wall thickness shall be (+)15% and (-) 0%. API Spec 5L Table 9 stands cancelled. Wall thickness shall be measured and recorded at least 3 times per operating shift (12 hours maximum). 7.5 LENGTH All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of the ordered quantity. The minimum average length of the entire ordered quantity in any case shall be 12.0m. API Spec 5L Table 11 shall not be applicable. Overall length tolerance shall be (-) Zero and (+) One pipe length to complete the ordered quantity. Each pipe shall be measured for conformance to above requirements and all measurements shall be recorded.
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7.6

STRAIGHTNESS The deviation from a straight line for all pipe sizes shall not exceed 12 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be measured and recorded at least 3 times per operating shift (12 hours maximum).

7.7

JOINTERS Jointers on pipes are not permitted.

7.8 7.8.1

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

7.8.2

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

7.8.5

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

7.8.7

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

7.8.8

Hard Spots Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot shall be removed as a cylinder.

7.8.9

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

7.8.10

Laminations
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Any lamination or inclusion either extending into the face or bevel of the pipe or present within 25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back until such defects are eliminated. The acceptance limit and disposition of lamination and other type of defects on the skelp/pipe body shall be as per para 9.8.5.4 of this specification. 7.8.11 Arc Burns Arc burns produced during the manufacturing of pipes are injurious defects and shall be disposed off in accordance with the requirements of API Spec 5L para 9.9 (c) or (d). As a reference method for conforming the existence of an arc burn, the area shall be buffed with wire brush or sanding disc and etched with 5 percent nital solution. However, arc burns can be considered for acceptance, in case the same is recrystallized by seam heat treatment. In such case, the Manufacturer shall demonstrate the recrystallization to Purchaser by taking a sample as per para 6.2.6.1 (New) of this specification. 7.8.14 Other Defects Any imperfection (measured from the surface) with a depth greater than 5 % of the specified thickness of the pipe shall be considered a defect and shall be repaired in accordance with API Spec 5L para 9.9 and as modified in this specification. 7.9 7.9.1 7.9.3 PIPE ENDS General Pipes shall be furnished with plain ends. Plain Ends Unless specified otherwise, the pipe ends shall be bevelled as per API Spec.5L. In removing the inside burrs at the pipe ends, care shall be taken not to remove excess metal and not to form an inside cavity or bevel. Removal of excess metal beyond the minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause for re-bevelling. In case root face of bevel is less than that specified, the pipe ends shall be re-bevelled and rectification by filing or grinding shall not be done. 7.9.6 Bevel Protectors (New) Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design such that they can be re-used by coating applicator for providing on externally anti-corrosion coated pipes subsequent to coating of line pipe.
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9 9.2 9.2.1

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

9.2.2 9.2.2.1

Product Analysis Sampling Frequency Two pipes per inspection lot shall be analyzed. Inspection lot shall be 100 pipes per heat. Pipes selected shall be such that one at the beginning of the heat and one at the end of the heat arc also represented.

9.2 2.2

Sampling Method Samples used for product analysis shall be taken from finished pipes. Samples for product analysis from skelp may be used provided the traceability of samples is guaranteed.

9.2.2.22 Welded Pipe

9.3 9.3.1

TESTING OF MECHANICAL PROPERTIES Tensile Tests Tensile properties shall be determined from specimen removed from pipe which has been subjected to all mechanical and heat treatment operations.

9.3.1.2

Tensile Testing Frequency Tensile tests shall be made at the frequency of two pipes per inspection lot. Inspection lot shall be 100 pipes per heat, API spec Table 13 stands modified accordingly.

9.3.1.3

Longitudinal Tensile Tests Longitudinal tensile tests shall be carried out on a strip specimen.

9.3.1.4 9.3.1.5

Transverse Tensile Tests The transverse tensile tests shall be carried out on flattened rectangular specimen. Weld Tensile Tests
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Inside and outside flash of weld in excess of pipe wall thickness shall be removed from the specimen either by grinding or machining. Specimen shall be tested for ultimate tensile strength only. 9.3.5 9.3.5. 1 Fracture Toughness Tests Charpy Test Specimens In addition to the specimen taken from the body of the pipe, three transverse specimens with weld in middle and three transverse specimens with Heat Affected Zone (HAZ) in the middle shall also be taken. When either full size or sub-size transverse specimen as per API Spec 5L, Table 14 is not possible to obtain, transverse specimen of either Size 1/3 or 1/4 Size, whichever is maximum possible, may be obtained. When such sub-size specimens are used, the acceptance of the individual / average absorbed energy values shall be established as per API Spec 5L para 9.10.4 and as modified in this specification. 9.3.5.2 Charpy Testing Frequency The minimum test frequency shall be one test (a set of three specimen each for body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. 9.4 9.4.1 HYDROSTATIC TESTS Hydrostatic Test Requirements Test pressure shall be held for a minimum period of 15 seconds for all sizes and grades of pipes. 9.4.2 Verification of Hydrostatic Test The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5 times and maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a "Dead Weight" tester only and record shall be maintained. 9.4.3 Test Pressure The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress) generated is at least 95% of SMYS, computed based on the formula mentioned in API Spec 5 L para 9.4.3 (Note 2). 9.5 DIMENSIONAL TESTING The measuring equipment requiring calibration or verification under the provisions of API Spec 5L shall be calibrated with manual instruments at least once per operating shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's Representative on request.
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9.8

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

9.8.1

Qualification of Personnel All personnel performing NDT activities shall be qualified in the technique applied, in accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent. All NDT shall be performed in accordance with written procedures. These procedures shall have prior approval of the Purchaser. Inspector Qualification Acceptable qualification for NDT inspectors shall be as specified below:

(i)

For UT
For UT, at least one level III qualified inspector shall be available to the mill for overall supervision. A level II inspector is required for shift supervision, manual weld inspection and calibration of all systems (both manual and automated).

(i)

For all other NDT methods


Evaluation of indications Supervision : : Level I, II, III inspector Level II or Level III inspector (in case evaluation is by Level I inspector)

9.8.3

Methods of Inspection Location of NDT equipment in the manufacturer's facility shall be such that final inspection of Weld seam of pipe shall be performed after hydro testing.

Plate/Skelp Inspection The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over a width of at least 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp
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shall be ultrasonically tested for laminations using an oscillating or straight running pattern of probes, so as to provide inspection coverage of at least 20% of the plate/skelp surface uniformly spread over the area. Locations showing indications above the acceptance limits may be re-examined by manual ultrasonic method. If no defects are located during re-examination, the original findings may be ignored. Additional scanning may be requested by Purchaser's Representative to check questionable areas. Pipe Ends Inspection The full circumference of both ends of each pipe after beveling shall be 100% ultrasonically tested for laminations from inside over a circumferential band of at least 25 mm width. Alternatively the pipe may be tested from outside prior to bevelling, in which case a band of at least 50 mm wide shall be tested to include the eventual bevelled area. Bevel Inspection Bevel face of all pipes shall be inspected by magnetic particle method to detect defects. Weld Inspection Electric welds shall be inspected by ultrasonic methods (Refer Table 24) using automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5, API Spec 5L SR 17 (Appendix F) and as modified in this specification. Pipe end welds shall be inspected in accordance with Para 9.8.3.1. 9.8.3.1 Pipe End Weld Inspection Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual ultrasonic equipment with same sensitivity and capability as automatic equipment. 9.8.5 9.8.5.1 Ultrasonic and Electromagnetic Inspection Equipment All automatic ultrasonic equipment shall have an alarm device, which continuously monitors the effectiveness of the coupling. The equipment for the automatic inspection shall allow the localization of both longitudinal and transverse defects corresponding to the signals exceeding the acceptance limits of the reference standard. The equipment shall be fitted with a paint spray or automatic marking device and alarm device for areas giving unacceptable ultrasonic indications. All ultrasonic testing equipment shall be provided with recording device. In addition, an automatic weld tracking system shall be provided for correct positioning of the probes with respect to weld centre. 9.8.5.2 Ultrasonic and Electromagnetic Inspection Reference Standards
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The reference standard (calibration pipe) shall have the same specified diameter and wall thickness as specified for the production pipe being inspected and shall be of sufficient length to permit calibration of ultrasonic inspection equipment at the speed to be used in normal production. The reference standard (calibration pipe) shall also be of the same material, type and have the same surface finish and heat treatment as the pipe being inspected. The reference standard for weld UT shall contain machined notches as per as per Figure 9.8.5.2 of this specification and as given below: One longitudinal inside notch of type N10 at the weld line One longitudinal outside notch of type N10 at the weld line The reference standard for skelp/pipe body UT shall contain continuous machined notch of 8 mm width x t depth, wheret is the specified wall thickness. The reference standard for skelp edge UT/ UT of area adjoining weld seam and pipe ends shall have 1/4 inch dia FBH x t depth, wheret is the specified wall thickness. The calibration shall be performed at following intervals: a. At the beginning of each operating shift (12 hours maximum). b. At least once during each operating shift (12 hours maximum). c. Every time the running of the system gives rise to doubts on its efficiency. If during the above calibration verification, it is found that the equipment has not functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes or skelp already inspected after the previous verification shall be inspected again at Manufacturer's cost. 9.8.5.4 Acceptance limits Acceptance limit for material edge examination shall be as per criteria laid down for Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready reference. 1. No individual imperfection of length less than 20 mm shall be considered for population density assessment. 2. Maximum length of imperfection in any direction shall not exceed 30 mm. 3. Maximum area of individual imperfection shall not exceed 500 mm2. 4. Maximum population density (number of imperfections smaller than the maximum permissible imperfection size and longer than 20 mm per 1m length) shall not exceed 4.
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9.8.5.4.1 Skelp Edges/Area on either side of the Longitudinal Weld Seam (New)

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Disposition of any defect shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.5.4.2 Skelp/Pipe Body (New) Acceptance limit for material body examination shall be as per criteria laid down for Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready reference: 1. No individual imperfection that does not exceed all of the following dimensions shall be considered for population density assessment: Area: 300 mm2, Length: 35 mm, Width: 8 mm. (The length is the dimension at right angles to the scan track and the width is the dimension parallel to the scan track.) 2. Maximum area of any individual discontinuity shall not exceed 1000 mm2. 3. Maximum population density of imperfections smaller than the maximum permissible imperfection size and larger than the minimum imperfection size per 1 m x 1 m square shall not exceed 10. 4. Any imperfection exceeding 100 mm in length shall not be acceptable and any planar imperfection not parallel to the plate surface is not acceptable. Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d). 9.8.7 e. Residual Magnetism Measurement Requirements The average of the four readings shall not exceed 20 gauss and no one reading shall exceed 25 gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be recorded. DISPOSITION OF PIPE CONTAINING DEFECTS The repaired area shall be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete removal of defects. However for repair of cosmetic type of defects, MPI may not be conducted if so directed by Purchaser's Representative on case to case basis. The pipes having a thickness less than the minimum allowed in accordance with this specification, after repair by grinding shall be treated for disposition in accordance with API Spec 5L Para 9.9 (c) or (d). 9.10 9.10.4 TEST METHODS Charpy Test Individual test value for any specimen shall not be less than 80% of the required minimum average absorbed energy value as per this specification.
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9.9

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9.12 9.12.1

RETESTS Recheck Analysis Modalities of recheck analysis shall be as per API Spec. 5L as applicable to the lot being tested (refer para 9.2.2.1 of this specification). However, during individual testing, each pipe shall be fully analysed to meet the requirements of Table 2B of this specification.

9.12.6

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

9.13 10 10.1

REPROCESSING This para stands cancelled. Marking GENERAL Marking specified in AP! Paragraphs and otherwise specified in the Purchase Order shall be in English language and international System (SI) of units. Marking shall comply with Appendix I of API Spec 5L and as modified in this specification.

11 11.1

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

12 12.1

Documents CERTIFICATION Manufacturer shall furnish to Purchaser a certificate of compliance stating that the material has been manufactured, sampled, tested, and inspected in accordance with this specification and has been found to meet the requirements. In addition all details as per Appendix F Supplementary Requirement SR 15 shall also be submitted to Purchaser/Purchaser Representative during inspection at pipe mill.
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12.2

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

12.3

PRODUCTION REPORT (New) The Manufacturer shall provide six copies of production report in English language indicating at least the following for each pipe. International System of units (SI) shall be adopted. Pipe number Heat number from which pipe is produced Pipe length and weight. Pipe grade

The Manufacturer shall provide six copies of acceptance certificates which shall include the results of all tests required as per this specification and performed on delivered material giving details of, but not limited to, the following: All test certificates as per SR 15.1. Certified reports of dimensional, workmanship and defects inspection. Data on test failures, rejected heats/lots, etc. All other reports and results required as per this specification.

The certificates shall be valid only when signed by the Purchaser's Representative. Only that pipes, which have been certified by the Purchaser's Representative shall be dispatched from the pipe mill. In the event of small quantities of pipes supplied against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the production report may consist of only test certificates required as per SR 15 of API Spec 5L and other test reports/results required as per this specification. 12.4 LINE PIPE TRACEABILITY DATA (New) The manufacturer shall establish and follow procedures for maintaining heat and lot identity of all pipes as per Supplementary Requirements SR 15.2 of API Spec. 5L. 14 Inspection of Field Tests & Warranty (New)
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Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order that fails under field hydrostatic test if such failure is caused by a material/manufacturing defect in the pipe. The reimbursement cost shall include pipe, labour and equipment rental for finding, excavating, cutting out and installation of replaced pipe in position. The field hydrostatic test pressure will not exceed that value which will cause a calculated hoop stress equivalent to 95 percent of specified minimum yield strength. In case Manufacturer so desires, he will be advised at least two weeks in advance so that his Representative may witness the hydrostatic test in field, however, the testing and leak (if any) finding and repair operation shall not he postponed because of absence of the Manufacturer's Representative.

APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE) SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 or Larger SR 5.1 SR 5.3 The Manufacturer shall perform Charpy V-notch test for determining Shear Area. The specimen shall be fall sized or largest obtainable sub size in case pipeline diameter and thickness does not permit full size specimen. In case it is not feasible to obtain transverse specimen, a longitudinal specimen may be taken upon approval from Purchaser. Flattened specimen shall not be used. This para stands deleted. Shear Area

SR 5.4 SR 5.5 SR 5A

SR 5A.1 Three transverse specimens representing one test shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. SR 5A.2 Unless specified otherwise in the Purchase Order, the specimen shall be tested at +32F (0C). The average shear value of the fracture appearance of the three specimens shall not be less than 75% and the all heat average for each order, per diameter, size and grade shall not be less than 80%. Note: The acceptance criteria of shear area as referred in API Spec. 5L para SR 5A.3 SR 5A.4 and SR 5A.5 stand modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec 5L SR 5A.3, SR 5A.4, SR 5A.5 and SR 5A.6 shall be replaced by 'lot'. Lot shall be as per SR5A.1 as above.
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SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE)

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SR6 SR6.1

Drop Weight Tear Testing (DWTT) on Welded Pipe When required as per para 6.2.5.3 of this specification, fracture toughness shall be determined using Drop Weight Tear Test (DWTT) by the Manufacturer for pipe size 16 and larger. DWTT shall be carried out in accordance with the requirements of API Spec 5L para SR 6.2 thru SR 6.8 and as modified in this specification. Two transverse specimen shall be taken from one length of pipe per heat per lot of 100 pipes per combination of pipe size and specified wall thickness. Unless specified otherwise, the test shall be conducted at +32F (0C). At least 80% of the lot (refer para SR 6.2 of this specification) shall exhibit a fracture appearance shear area of 75% or more for the specified test temperature. Acceptance criteria for retesting indicated in API Spec 5L para SR 6.5 stands modified based on above mentioned requirements. Wherever 'heat' indicated in API Spec SR6.5 shall be replaced by 'lot1. Lot shall be as per SR6.2 as above.

SR 6.2

SR 6.4 Note:-

SR17 SR 17.1

Nondestructive Inspection of Welds in Electric Welded Pipe and Laser Welded Pipe SUPPLEMENTARY NON DESTRUCTIVE INSPECTION The weld in electric welded pipe shall be inspected full length for surface and subsurface defects and laminations by ultrasonic methods using automatic ultrasonic equipment.

SR 17.2

EQUIPMENT AND REFERENCE STANDARDS The equipment for ultrasonic inspection shall meet the requirements of para 9.8.5.1 and 9.8.5.2 of this specification. The detailed procedure shall be approved by Purchaser's Representative.

SR 17.3 ACCEPTANCE LIMITS If during production, repeated ultrasonic indications occur requiring re-inspection by other methods and it appears that the nature of defects causing ultrasonic indications can not be definitely established, the Manufacturer shall prove by other inspection methods (such as making cross-sections as per para 6.2.6.1 of this specification) that these defects are not injurious defects as stipulated in this specification. SR 17.4 DISPOSITION Disposition of defects shall be in accordance with API Spec 5L para 9.9 (c) or (d). SR19 Additional Fracture Toughness Requirements (Transverse Charpy V-Notch) for PSL 2 Pipe
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SR 19.1

Except as allowed by SR. 19.2 of API Spec 5L, fracture toughness testing shall be performed in accordance with the requirements of para 9.3.5.1 and 9.3.5.2 of API Spec 5L and as modified in this specification, with a test temperature of 32F (0C) or at a lower temperature as specified in the Purchase Order. The required minimum all heat average full size absorbed energy value (based on a set of three specimens) for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API Spec. 5L, the minimum average absorbed energy value shall be 1.5 times that applicable for transverse specimen. The required minimum all heat average full size absorbed energy value for weld and HAZ specimen shall also be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual absorbed energy value of the three specimens shall not be less than 80% of the value specified.

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APPENDIX- H PURCHASER INSPECTION (NORMATIVE) H.4 Rejection If Purchaser Representative rejects pipes repeatedly for any recurring cause, this shall be adequate reason to refuse final inspection of subsequent pipes until the cause has been investigated and corrective action taken by the Manufacturer.

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APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE) 1.1 1.1.1 General Marking shall also include API monogram, Purchase Order number, item number, wall thickness (mm), pipe number, heat number and weight. Location of Markings Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis. Stencil marking shall be placed on the inside surface length except that on pipe size smaller than 16, marking may either be placed on inside or outside. Paint used for stencil marking shall withstand a temperature up to 2505C expected to be experienced during further external anti-corrosion coating operations of line pipe by coating applicator. 1.3 1.3.4 Sequence of Marking SPECIFIED DIMENSIONS Actual pipe weight in kg shall also be marked. 1.35 GRADE AND CLASS A colour code band shall be marked on inside surface of finished pipe for identification of pipes of same diameter but different wall thickness, as indicated in the Purchase Order. The colour code band shall be 50 mm wide and shall be marked at a distance of 150 mm from the pipe ends. 1.5 1.7 Length Actual length shall be marked in metres. Die Stamping Additionally, the pipe number shall be placed by cold rolling or low stress dot marking on the outside surface of the pipe at an approximate distance of 50 mm from both ends. In case of non-availability of either cold rolling or low stress dot marking facility in pipe mill, an alternative marking scheme of a permanent nature may be proposed by the Manufacturer.

1.2

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ANNEXURE I (NEW) MANUFACTURING PROCEDURE SPECIFICATION A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated inspection procedures from steel making to finished line pipe shall be prepared and submitted to Purchaser for approval prior to start of production. Manufacture of pipes shall start only after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall be strictly followed in all phases of the production of pipes. The manufacturing procedure shall as a minimum include the following information. - Steel/Plate/skelp maker and plant at which steel is produced. - Steel making process with details of secondary refining process and continuous casting process, nominal weight of each heat. - Target chemistry, range of intentionally added elements, limits on heat and product analysis to be placed on steel maker. Skelp rolling procedure indicating number of passes, their temperature and thickness reduction in each pass required by Controlled Rolling Procedure and the finishing temperature. - Heat treatment procedure document established as per para 5.4. - Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including details of equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference standard for calibration, dynamic calibration procedure, method of marking defects and indicating loss of coupling, inspection and recording. - Pipe making procedure including skelp edge preparation, forming and any other special process proposed. - Welding procedure specification including the details of welding process, brand name, classification, size and grade of filler metal and flux, speed of welding, number of electrodes and polarity of each electrode, welding current and voltage for each wire, edge preparation, tack welding method and spacing of tack weld, details of seam tracking system for both inside and outside welding, method of checking the setup of the system, limits of internal and external weld reinforcement etc. In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by approved welders of the EPC Contractor to establish the weldability of pipe. EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe mill. Establishing the WPS of pipe mill doesnt absolve the EPC contractor of his responsibility of carrying out WPS / PWR at site.
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- Method of weld defect removal. - Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect and indicating loss of coupling, inspection and records. - Full details of radiographic testing equipment including radiographic film. - Dimensional tolerances, frequency of checking, measurement and record in a tabular form including details of instruments and equipments proposed. - Detail of techniques proposed for measurement of end square ness and peaking at the welds. - Hydrostatic testing including details of testing equipment, procedure and the relevant test pressure calculations. - Marking details. - Handling, storage and shipment procedure. - Production Report Formats. - Complete details of computerized pipe tracking system. Note: In the event of small quantities of pipe ordered against this specification, the requirements of submission of manufacturing procedure details can be moderated subject to agreement between Purchaser and Manufacturer.

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

DOCUMENT No. S-04-02-004

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ANNEXURE-lI (NEW) FIRST DAY PRODUCTION TESTS Two lengths each of completely finished pipes of first day's production from two different heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the manufacturing procedure results in the quality of pipes which are in complete compliance with this specification. The pipes thus tested shall be considered to be the test pipes required per heat or per lot as per relevant clauses of this specification. The first day's production tests shall be repeated upon any change in the manufacturing procedure as deemed necessary by Purchaser Representative. The first day production tests shall be carried out on pipes for each wall thickness, each diameter and each grade of steel, The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned below. The report shall be agreed and signed by Purchaser Representative, prior to start of regular production. Note: In the event of small quantities of pipes ordered against this specification, like those for bends and other similar applications, as specifically called out in the Purchase Order, the first day production test shall not be carried out. Pipes in such case shall be accepted based on regular production tests. The various tests to be conducted on each pipe shall be as follows. The test method and acceptance values shall be as per this specification unless specified differently in this Annexure. a. Visual Examination All pipes shall he examined visually for dimensional tolerances and apparent surface defects. b. Ultrasonic Examination The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment. c. Mechanical Properties The mechanical properties of all pipes shall be tested and shall meet the requirements of this specification. Purchaser Representative will select the places in pipe from where the test specimen shall be removed. The following tests shall be conducted: i. ii. Two (2) flattening test specimen shall be removed; one specimen shall be tested with weld at 0 and other at 90. Two (2) transverse base metal specimen and two transverse weld specimen for tensile test shall be tested. In case transverse base metal specimen is not applicable as per Fig 3 of API Spec 5L, longitudinal specimen may be taken.
SPECIFICATION FOR ELECTRIC WELDED (EW) LINE PIPE (ONSHORE) DOCUMENT No. S-04-02-004 REV-0 Page 30 of 34

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iii.

Six (6) weld cross-section specimen, three (3) from each end of the pipe joint, shall be taken for metal!-'graphic examination. Two of these specimens shall be tested for hardness at room temperature after etching.

iv. -

Fracture toughness testing specimen shall be extracted as follows: Four sets of three transverse specimen each from base metal One set of 3 transverse specimen with weld in middle One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 20 C for shear area and absorbed energy to produce full transition curve. The value at the test temperature specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification for shear area and absorbed energy respectively shall be complied with. For other temperatures, the value shall be for information only. The sets of weld and HAZ specimen shall be tested for absorbed energy only at the same test temperature applicable as per SR 19 of API Spec. 5L. v. At points selected by Purchaser, twelve (12) DWTT specimens shall be removed from base metal in a transverse direction. The sets of 3 base metal specimen shall be tested at -40. -10, 0, +20C for shear orp t0 produce full transition curve. The value at the test temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be complied with. For other temperatures, the value shall be for information only (Note: This test is to be carried out only when required as per para 6.2.5.3 of this specification) vi. Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this specification. e. In addition, all the tests and inspections require to be conducted as per this specification shall be conducted on all the pipes selected for testing during first day production test.

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

DOCUMENT No. S-04-02-004

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GAIL (INDIA) LTD NEW DELHI

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

DOCUMENT No. S-04-02-004

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

DOCUMENT No. S-04-02-004

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

DOCUMENT No. S-04-02-004

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3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

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3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

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CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 SCOPE REFERENCE DOCUMENTS PLANT SCALE AND INSTALLATION MATERIALS FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING MEASUREMENT AND LOGGING COATING PROCEDURE AND QUALIFICATION PIPE SURFACE PREPARATION COATING APPLICATION INSPECTION AND TESTING HANDLING, TRANSPORTATION AND STORAGE REPAIR OF COATING MARKING QUALITY ASSURANCE COMBINATIONS OF COATING MATERIALS

ANNEXURE-I

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1.0

SCOPE This specification covers the minimum requirements for supply/arrangement of all materials, plant, equipment, plant sites, consumables, utilities and application including all labour, supervision, inspection and tests etc. for application of external anti-corrosion coating of pipes by using 3 Layer Side Extruded Polyethylene coating conforming to DIN-30670, 1991, 'Polyethylene Coating for Steel Pipes and Fittings' and the requirements of this specification.

2.0

REFERENCE DOCUMENTS Reference has also been made to the latest edition of the following standards, codes and specifications. The edition enforce at the time of floating the enquiry shall be termed as latest edition. a. ASTM D-149 : Standard Test Methods of Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Frequencies. : Standard Test Methods for D-C Resistance or Conductance of Insulating Materials. : Standard Method of Test for Resistance of Plastics to Chemical Reagents. : Standard Method of Test for Water Absorption of Plastics. : Standard Method of Test for Tensile Properties of Plastics.

b. ASTM D-257 c. ASTM D-543 d. ASTM D-570 e. ASTM D-638 f. ASTM D-792

: Standard Test Method for Density and Specific Gravity (Relative Density) of Plastics by Displacement. : Test Method for Flow Rates of Thermoplastics by Extrusion : Test Method for Vicat Softening Temperature of Plastics : Test Method for Carbon Black in Olefin Plastics : Test Method for Environmental Stress Cracking of Ethylene Plastics : Test Method for Rubber Property Durometer Hardness : Test Method for Oxidative-induction Time of Polyolefins by Differential Scanning Calorimetry

g. ASTM D-1238 h. ASTM D-1525 i. ASTM D-1603 j. ASTM D-1693 k. ASTM D-2240 l. ASTM D-3895 m. ASTM G-42

: Tentative Methods for Cathodic Disbonding of Pipeline coatings Subjected to Elevated or Cyclic Temperatures.
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n. API RP 5L1 o. API RP 5LW p. DIN EN 10204 q. DIN 53735 r. ISO 8502-3

: Recommended Practice for Railroad Transportation of Line pipe. : Transportation of Line Pipe on Barges and Marine Vessels : Metallic Products Types of Inspection Documents : Testing of Plastics: Determination of Melt Index of Thermoplastics. : Preparation of Steel Stubstrates before Application of Paints and Related Products -

Part 3 - Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method) s. ISO 9002 t. ISO 11124 u. SIS 055900 : Quality Systems : Specification of Production and Installation : Preparation of Steel Substrates Before Application of Paints and Related Products : Preparation of Steel Substrates before Application of Paints and Related Products -Visual Assessment of Surface Cleanliness : Specification for Line Pipe : Gas Transmission and Distribution Piping Systems.

v. API 5L w. ASME B31.8 x. ASME B31.4

: Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols : External Fusion Bond Epoxy Coating for Steel Pipe.

y. CSA Z245.20-98

The CONTRACTOR shall be familiar with the requirements of these documents and shall make them readily available at the coating plant to all persons concerned with carrying out the works specified in this specification. 3.0 3.1 PLANT SCALE AND INSTALLATION CONTRACTOR shall size coating plant(s) after evaluating the scale of work and the time schedule required for the works. Coating plant(s), both new or existing, shall be installed into a yard whose geometry and dimensions are such as to allow the execution of a continuous work schedule. For this purpose the CONTRACTOR shall ensure non-stop work execution owing to prohibitive adverse weather conditions and install requisite equipment and plant in roofed and adequately weather protected areas.
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3.2

Plant equipment, machinery and other facilities shall be in first class operating condition to at least meet the job requirements of quality and production. Worn out and improvised plants are not acceptable. The CONTRACTOR shall, at his own responsibility and cost, provide and prepare all necessary area for the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other temporary installation. For each area, CONTRACTOR shall provide necessary agreements as required with the land owner(s) / relevant Authorities, and, on work completion, to clean and pay settlement and claims for damages, as applicable. The CONTRACTOR shall at its own responsibility and cost, provide for water and power supply and other utilities and consumables and obtain authorization regarding access roads and other permits required for the execution of works conforming to all the requirements of the governing Authorities. The CONTRACTOR shall at its own expense provide a fully equipped laboratory and test facilities with adequate inventory to carry out tests required for the procedure qualification and regular production. Outside testing for qualification and regular production is not acceptable to COMPANY. The CONTRACTOR shall be fully responsible for adherence to all statutory regulations applicable for handling and disposal of the hazardous chemicals during the coating works. The CONTRACTOR shall be responsible for obtaining all statutory approvals / clearances from relevant Authorities including Pollution Control Board, as applicable for the coating plant(s). MATERIALS The three layer coating system shall comprise of a powder epoxy primer, polymeric adhesive and a polyethylene top coat. Coating materials shall be suitable for the service conditions and the pipe sizes involved. The coating materials i.e. epoxy powder, adhesive and polyethylene compound shall have proven compatibility. The coating system and materials shall be pre-qualified and approved by COMPANY in accordance with provisions Annexure I of this specification. CONTRACTOR shall obtain prior approval from COMPANY for the coating system and coating materials, The coating materials Manufacturer shall carry out tests for all properties specified in para 5.3.1 and 5.3.2 for each batch of epoxy, adhesive and polyethylene compound. In addition, the Manufacturer shall also furnish Infrared Scan for each batch of epoxy powder. The coating materials Manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for each batch of materials supplied to CONTRACTOR and the same shall be submitted to COMPANY for approval prior to their use. In addition to Manufacturer's certificate, the CONTRACTOR shall draw samples from each batch of epoxy, adhesive and polyethylene in the presence of COMPANY Representative and test for the following properties at the coating yard at least one week prior to its use, to establish compliance with the Manufacturer's test
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3.3

3.4

3.5

3.6

3.7

4.0 4.1

4.2

4.3

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certificates. a. Epoxy Powder: i. Gel Time ii. Cure time iii. Moisture content iv. Thermal Characteristics (Tg1, Tg2 , H) b. Adhesive: i. Specific Gravity ii. Melt Flow Rate iii. Vicat Softening Point c. Polyethylene: i. Melt Flow Rate ii. Specific Gravity iii. Vicat Softening Point iv. Moisture Content v. Oxidative Induction Time In case of failure of any of the above tests in a batch, that batch of material shall be tested for all other tests required as per para 5.3.1 and 5.3.2 including the tests which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating. 4.4 All materials to be used shall be supplied in sealed, damage free containers and shall be suitably marked with the following minimum information: a. Name of the Manufacturer b. Type of Material c. Batch Number d. Place and Date of Manufacture e. Shelf Life/Expiry Date (if applicable) f. Quantity All materials noted to be without above identification shall be deemed suspect and shall be rejected by COMPANY. Such materials shall not be used for coating and shall be removed from site and replaced by CONTRACTOR at his expense. 4.5 CONTRACTOR shall ensure that all coating materials are properly stored in accordance with the Manufacturer's recommendation at all times, to prevent damage and deterioration in quality prior to use.
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4.6 5.0 5.1

CONTRACTOR shall be required to use all materials on a date received rotation basis, i.e. first in- first used basis. FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING The coating shall be able to withstand a maximum in service operating temperature of (+)650C and shall conform to 'S Type of coating as per DIN 30670. In addition, in open storage the coating must be able to withstand a temperature of at least (+)80C, without impaling its serviceability and properties specified. The top coat polyethylene used shall be a black readymade compound, fully stabilized against Influence of ultraviolet reaction (i.e. sunlight), oxygen in air and heat (due to environmental temperature as specified above). No appreciable changes shall occur during exposure to such environments up to at least a period of 6000 hours. The CONTRACTOR shall submit certificate from Manufacturer in this regard. Properties Properties of coating system and coating material shall comply the requirements indicated in subsequent paragraphs. In case the coating / material properties are tested as per test methods / standards other than specified herein below, the same may be accepted provided the test procedures and test conditions are same or more stringent than the specified.

5.2

5.3

5.3.1

Properties of Epoxy Powder and Adhesive CONTRACTOR shall choose such a brand of epoxy powder and adhesive that will achieve the functional requirements and properties of coating system as specified in para 5.1 and 5.3.3 of this specification respectively. Epoxy powder properties shall be as per CSA Z245.20.98. The colour of epoxy powder shall be either green or dark red or any other colour approved by COMPANY except grey colour. Copolymer grafted adhesive shall have the following properties: SI. No. a. b. c. Properties Melt Flow Rate (190C/2.16kg) Vicat Softening Point Specific Gravity Unit g/10 minutes C Requirement 1 .0 min. 100 min. 0.926 min. Test Method ASTM D1238 ASTM D1525 ASTM D 792

5.3.2

Properties of Polyethylene Compound SI. No. Properties Unit Requirement Test Method

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3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

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a. b.

Tensile Strength @ + 25 C Melt Flow Rate (190DC/2.16kg) Specific Gravity @ + 25C

N/mm2 9/10 minutes

17 min. 0.25 min. 0.926 min. (MDPE) 0.941 min. (HDPE) 50 min. 0.05 max. 1016min.

ASTM D 638 ASTM D 1238 or DIN 53735

c.

ASTM D 792

d. e.

Hardness @ + 25 C Water Absorption, 24 hours, @ + 25 C Volume Resistivity @ + 25C Dielectric withstand, 1000 Volt/sec rise @ + 25C Vicat Softening Point Elongation Oxidative Induction Time in Oxygen at 220C, Aluminum pan, no screen Environmental Stress Crack Resistance (ESCR) (for F 50) : -Medium DensityCondition "C -High DensityCondition "B" Carbon Black Content

Shore D %

ASTM D 2240 ASTM D 570

f.

Ohm-cm

ASTM D 257

Volts/ mm

30,000 min.

ASTM D 149

h. i.

C %

110 min. 600 min.

ASTM D 1525 ASTM D 638

j-

Minutes

10

ASTM D3895

k.

300 Hours 300 % 2 min. ASTM D 1603 ASTM D1693

l.

5.3.3

Properties of Coating System


3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE) DOCUMENT No. S-04-02-005 REV-0 Page 8 of 34

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SI. No.

Properties

Unit

Requirement

Test Method

Bond Strength (using Type 2 Test Assembly a. i.e. Dynamometer) . @20+/-5C . @65+/-5C Impact Strength (Min. of 30 impacts on b. body along the length. No breakdown allowed when tested at 25 Kv) c. d. e. Indentation Hardness @23+/-2C @70+/-2C Elongation at Failure Coating Resistivity (*)

Kg/cm

8.0 min 5.0 min

DIN 30670

Joules per mm of coating thickness

7 min

DIN 30670

mm % Ohm - m2

0.2 max 0.3 max 300 min. 10 8 min. Melt Flow Rate shall not deviate by more than 35% of original value Melt Flow Rate shall not deviate by more than 35% of regional value 15 max.

DIN 30670 DIN 30670 DIN 30670

f.

Heat Ageing (*)

DIN 30670

9-

Light Ageing (*)

DIN 30670

h.

Cathodic Disbondment @ + 65 C after 30 days @ + 65C after 48 hrs Degree of Cure of Epoxy. Percentage Cure, H. Tg

mm radius of disbondment (**)

ASTM G42 7 max.

% C

95 +3/-2

CSA Z 245.20-98(***)

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3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

DOCUMENT No. S-04-02-005

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(*) Test carried out in an independent laboratory of national / international recognition on PE top coat is also acceptable. (**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G42. (***) Temperature to which the test specimens are to be heated during cyclic heating shall however be as per the recommendations of epoxy powder manufacturer. 6.0 MEASUREMENT AND LOGGING CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipe coating including pipe number, heat number, diameter, length, wall thickness, defects, coating number, batches of materials, sampling, testing, damages, repairs, rejects and any other information that COMPANY considers to be relevant and required for all incoming bare pipes and COMPANY approved outgoing coated pipes as applicable. CONTRACTOR'S documentation shall be designed to ensure full traceability of pipe and coating materials through all stages of coating and testing. CONTRACTOR shall submit this information in the form of a report at the agreed intervals. The above data shall also be provided in MS ACCESS format in Compact Disc (CD). CONTRACTOR shall provide one Computer Terminal to COMPANY Representative for monitoring/tracking of the above. The CONTRACTOR shall also submit the material balance details to COMPANY for information at the end of each shift. 7.0 7.1 COATING PROCEDURE AND QUALIFICATION Upon award of the CONTRACT, the CONTRACTOR shall submit within two (2) weeks, for COMPANY approval, a detailed report in the form of bound manual outlining, but not limited to, the following: Details of plant(s), location(s), layout, capacity and production rate(s). Details of the equipment available to carry out the coating works including surface preparation, epoxy powder application and its recycling system, adhesive & polyethylene extrusion, moisture control facilities available for coating materials. Details of process control and inspection equipment required for the coating process such as temperature control, thickness control, holiday testers, etc Details of chemical pre-treatment facilities including process control and inspection equipment for phosphoric acid wash, de-ionised water wash and chromate wash. Facilities in the yard for unloading, handling, transport, production, storage, stockpiling, loading of bare and coated pipes and warehouses for storage of other coating materials. Plant Organization Chart and availability of manpower including coating specialist Details of utilities/facilities such as water, power, fuel, access roads and communication etc.
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a. b.

c. d. e.

f. g.

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After approval has been given by COMPANY, no change in plant set-up shall be made. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.2 At least four (4) weeks prior to the commencement of production coating, a detailed procedure of the CONTRACTOR'S methods, material proposed, etc., shall be formulated by the CONTRACTOR and submitted for COMPANY approval in the form of a bound manual. The procedure shall include, but not limited to, the following information and proposals: a. Pipe inspection at the time of bare pipe receipt. b. Steel surface preparation, including preheating, removal of steel defects, method of pipe cleaning, dust removal, abrasive blast cleaning and surface profile; methods of measurements and consumables. c. Complete details of chemical pre-treatment viz phosphoric acid wash, de-ionized water wash, and chromate wash including product data sheets, health and safety sheets and manufacturer's recommended application procedure. d. Pipe heating, temperatures and control prior to epoxy application. e. Complete details of raw materials including current data sheets showing values for all the properties specified together with quality control and application procedure recommendations from manufacturer(s). f. Application of FBE powder, adhesive and polyethylene, including characteristics, temperature, line speed, application window, curing time, etc. g. Quenching and cooling, including time and temperature. h. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting formats, including instrument and equipment types, makes and uses, etc i. Detailed method of repair of coating defects duly classified depending upon nature and magnitude of defects and repair thereof including coating stripping technique Details of instrument and equipment calibration methods including relevant standards and examples of calibration certificates.

j.

k. Complete details and inventory of laboratory and equipment for procedure qualification and regular production l. Pipe handling and stock piling procedure. m. Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification. n. Complete details of test certificate for raw material including test methods and standard used. o. Test certificates from PE compound manufacturer for tests for thermal aging, coating resistively and aging under exposure to light. These test certificates shall not be older than three years.
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p. Health, Safety and Environment Plans. q. Storage details of coating materials and chemicals. r. Continuous temperature monitoring at various stages of coating Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of the above procedure from COMPANY. No change in the procedure shall be made after approval has been given by the COMPANY. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.3 Prior to start of production, the CONTRACTOR shall, at his expense, carry out a coating PQT for each pipe diameter on max. wall thickness, for each type of pipe, for each coating material combination, and for each plant; to prove that his plant, materials, and coating procedures result in a quality of end product conforming to the properties stated in clause 5.3, relevant standards, specifications and material manufacturer's recommendations. CONTRACTOR shall give seven (7) working days notice to witness all procedures and tests. A batch representing a normal production run, typically 15 pipes, shall be coated in accordance with the approved coating procedure and the coating operations witnessed by COMPANY Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers. At least 5 (five) test pipes shall be selected by COMPANY Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. All tests shall be witnessed by the COMPANY Representative. Out of 5 (five) test pipes, 1 (one) pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers shall be included. Remaining 4 (four) test pipes shall have all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a part of coating operations as detailed subsequently. 7.4 7.4.1 Qualification of Procedures Epoxy Powder Application & Recycling During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of monitoring system, line speed vs coating thickness, etc. shall be established. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be recorded during the PQT. Also, the CONTRACTOR shall remove samples of reclaimed powder from the reclamation system. These samples of reclaimed powder shall be subject to a detailed visual examination, thermal analysis and moisture content tests. The properties of the reclaimed powder shall be within the range specified by the Manufacturer of epoxy powder. In case the properties of the reclaimed powder are out of the range specified by the Manufacturer, CONTRACTOR shall not use the reclaimed powder during the regular production. 7.4.2 Pipe Pre-heating The CONTRACTOR shall establish the temperature variation due to in-coming pipe
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temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc. and document the same during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and recording system including alarm/hooter shall be demonstrated to the COMPANY Representative. 7.4.3 Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance with the requirements of this specification. The ratio of shots to grits shall be established during procedure qualification testing, such that the resultant surface profile is not dished and rounded. The qualification shall be performed through a visual inspection, measurement of roughness and check of the presence of dust in the abrasive blast cleaned pipe surface. 7.4.4 7.4.4.1 Chemical Pre-treatment Phosphoric Acid Wash followed by De-ionised Water Wash The procedure to apply the chemical pre-treatment viz. phosphoric acid wash followed by de-ionised water wash shall be In accordance with the recommendations of the manufacturer and shall result in intended cleaning requirements of this specification. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the cleanliness/temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line speed vs. dwell time, rinsing procedure, testing & control, rectificatory measures, drying procedure etc. shall be clearly established during PQT. Also the quality of the deionised water shall be established during PQT. 7.4.4.2 Chromate Treatment The procedure to apply the chromate treatment shall be in accordance with the recommendations of the manufacturer. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs. line speed, pipe heating after chromating and time limit within which the pipe to be heated, testing & control, rectificatory measures, shall be clearly established during PQT. 7.4.5 Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, preheating pipe surface temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature and flow rate of co-polymer adhesive and polyethylene, etc. and the same shall be recorded. These values shall be complied with during regular production. 7.5 7.5.1 Qualification of Applied Coating Tests on pipe coated partly with epoxy and partly with epoxy & adhesive Layers
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a. Degree of Cure Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (Tg) and % cure (H) shall comply with the specified requirements. b. Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12 o'clock positions. The thickness shall comply with the specified thickness requirements. c. Adhesive layer Thickness Adhesive layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12'o clock positions. The thickness shall comply with the specified thickness requirements. d. Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall be set to exceed 5 v/micron of epoxy thickness specified for the portion coated only with epoxy layer. e. Adhesion Test i. Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. ii. Adhesion of FBE shall also be separately determined at ambient temperature at two locations by the "St Andrews Cross" method and the test shall comply with the specified requirements. f. 2.5 Flexibility Test 2.5 Flexibility test shall be carried out on the epoxy coated pipe at test temperature of 0C. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. g. Cross-section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98. Table 4. 7.5.2 Tests on pipes coated with all three layers a. Bond Strength: Three test pipes shall be selected for bond strength tests. On each of the selected pipes, three bond strength test shall be performed for each specified temperature I.e. one at each end and one in the middle of the pipe and specified
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requirements shall be complied with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65 mm. None of these samples shall fail. b. Impact Strength: Three test pipes shall be selected for impact strength test and the test shall meet the specified requirements. c. Indentation Hardness: Two samples for both temperatures from all pipes shall be taken. If any one of these samples fail to satisfy the specified requirements, then the test shall be repeated on four more samples. In this case, none of the samples shall fail. d. Elongation at failure: Six samples each from three coated pipes i.e. 18 samples In all shall be tested and the test shall comply the specified requirement. Only one sample per pipe may fail. e. Cathodic Disbondment Test: Two CD tests shall be carried out for the total lot of test pipes having all three layers. One test shall be carried out for 30 days duration and another test for 48 hours duration. The tests shall comply the specified requirement. Whenever Procedure Qualification is necessitated for different pipe size with same coating material combination, 48 hours test only be conducted. 30 days CD test is not mandatory in this case. f. Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in para 10.4, (b). g. Coating Thickness Measurement All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be as per para 10.3. h. Air Entrapment One sample each from pipe body and on weld (if applicable) shall be taken from all four coated pipes and the specified requirements shall be complied with. i. Degree of Cure Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (Tg) and % cure (H) shall comply with the specified requirements. 7.5.3 Inspection of all test pipes All pipes shall be subject to the following Inspections:
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Copyright GAIL All rights reserved

a.

Surface cleanliness, surface roughness measurements and dust control immediately after second abrasive blast cleaning and salt test immediately after De-ionised water wash. pH of pipe surface before and after phosphoric acid wash. visual inspection of chromate coating. Visual inspection of finished coating, cut back dimension, internal/external cleanliness, end sealing and bevel inspection. Acceptance criteria for all inspection and testing shall be as specified in this specification.

b. c. d.

7.6

After completion of the qualification tests and inspection as per para 7.4 and 7.5 above, the CONTRACTOR shall prepare and Issue to COMPANY for approval a detailed report of the above tests and inspection including test reports/certificates of all materials and coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall commence production coating. On successful completion of PQT, coating of all five (5) test pipes shall be removed and completely recycled as per the approved coating procedure specification, at CONTRACTOR'S expense. Remaining pipes will be accepted by COMPANY provided they meet the requirements of this specification and need not be stripped and re-cycled. The CONTRACTOR shall re-establish the requirements of qualification and in a manner as stated before or to the extent considered necessary by COMPANY, in the event of, but not limited to, the following: Every time there is a change in the previously qualified procedure. Every time there is a change in the manufacturer and change in formulation of any of the raw materials and change in location of raw material manufacture. Every time the coating yard is shifted from one location to the other or every time the critical coating equipments (induction heater, epoxy spray system, extruder, etc) are shifted. Any change In line speed during coating application Any time when in COMPANY'S opinion the properties are deeded to be suspect during regular production tests.

7.7

7.8

7.9

COMPANY reserves the right to conduct any or all the test required for qualification through an independent laboratory or agency at the cost of CONTRACTOR when in COMPANY's opinion, the results are deemed suspect. COMPANY's decision shall be final. PIPE SURFACE PREPARATION Unless specified otherwise, the pipes shall be supplied free from mill applied oils but
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8.0 8.1

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may be subject to contamination occurring during transit. 8.2 Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall ensure that all defects, flats and other damages have been repaired or removed. The CONTRACTOR shall also remove marking stickers, if any, present within the pipe. Record shall be kept of such marking on the stickers to ensure traceability of pipe after coating. Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond or coating quality shall be removed prior to coating application. Contaminants may be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning. All pipes shall be preheated to a temperature of 65C to 85C prior to abrasive blast cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blast cleaning units to achieve the specified surface cleanliness and profile. After first abrasive blast cleaning, chemical pre-treatment with phosphoric acid solution as per para 8.6 shall be carried out prior to second abrasive blast cleaning. However at the option of CONTRACTOR, chemical pre-treatment with phosphoric acid solution as per para 8.6 may be carried out after the second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection system to ensure total removal of dust generated during blast cleaning from the pipe surface. The equipment used for abrasive blast cleaning shall meet the specified requirements and shall be free from oil, water soluble salts and other forms of contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be checked for condensed water and oil at the start of each shift and emptied and cleaned regularly. During abrasive blast cleaning, the metallic abrasive shall be continuously sieved to remove "fines" and "contaminants" and the quality checked at every four hours. Abrasives used for blast cleaning shall comply ISO11124 8.5 Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into the pipe during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively the CONTRACTOR may link the pipes suitably together to prevent the entry of any shot/grit into the pipe. Chemical Pre-treatment with Phosphoric Acid Solution All pipes shall be provided chemical pre-treatment with phosphoric acid solution. 10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used to remove all soluble salts and other soluble contaminants. The CONTRACTOR shall provide data sheets and supporting documentation for the phosphoric acid to be used. The documentation shall verify that the phosphoric acid is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification.
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8.3

8.4

8.6 8.6.1

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8.6.2.1

The pipe temperature immediately prior to the phosphoric acid treatment shall be in the range of 450 to 750C. Phosphoric acid treatment shall be followed immediately by washing with de-ionised water. Deionised water used shall conform to the following requirements:

SI.No. a. b. C
d.
e. f.

Properties Turbidity Conductivity Hardness


Total Alkalinity as CaC03 Chloride as CI"

Unit NTU mho/cm mg/l mg/l mg/i -

Requirement 1 max. 5 max. Nil


2 to 3

1 max. 1 max.
6.5 to 7.5

Sulphate as SO4 pH

g.

Tests to determine the above properties shall be carried out in accordance with "Standard Methods for the Examination of Water and Wastewater" published jointly by American Public Health Association, American Water Works Association and Water Pollution Control Federation. Quality of the deionised water shall be monitored at the start of each shift and at every four hours interval. Non-compliance of deionised water wrt the above requirements shall cause for stoppage of the operations. 8.6.3 The pH of the pipe surface shall be determined both before and after the de-ionised water rinse initially on each pipe and in case of consistent results, the frequency may be relaxed to once per hour at the discretion of COMPANY Representative. The measured pH shall be as follows: Before de-ionised water wash : After de-ionised water wash 8.6.4 8.6.5 : 1 to 2 6 to 7

After the deionised water wash, the pipe shall be dried with dry air and preheated to a temperature of 65C to 85C. The salt tests shall be carried out after deionised water rinse. One test shall be carried out at one end of each pipe. The acceptance criteria shall be 2g/cm2. An approved salt meter (SCM 400 or equivalent) shall be used to carry out salt tests and shall be calibrated in accordance with the equipment manufacturer's recommendations. Abrasive cleaning carried out shall be such that the resultant surface profile Is not dished and rounded when viewed with 30X magnification. The standard of finish for

8.7

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DOCUMENT No. S-04-02-005

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cleaned pipe shall conform to near white metal finish to Sa 2 of Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive blast cleaning shall have an anchor pattern of 50 to 70 microns (Rz), This shall be measured for each pipe by a suitable instrument such as surface profile depth gauge. In addition the pipe surface after blast cleaning shall be checked for the degree of cleanliness (Sa 2 ), degree of dust and shape of profile. Degree of dust shall comply the requirements of ISO 8502 - 3. Acceptance limit shall be either quality rating 2 or Class 2. 8.8 All pipes shall be visually examined for presence of any shot/grit/loose material left inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to remove the same before the pipes are processed further. In addition, inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. Any foreign material or shots/grit present in the pipe shall be completely removed by mechanical brush, high pressure air jets, by tilting of pipe, etc. At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The CONTRACTOR shall measure the ambient conditions at regular intervals during blast cleaning and coating operations and keep records of prevailing temperature, humidity and dew point. The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or any other foreign material, nor shall the surface or its anchor pattern be scarred or burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to coating. After blast cleaning, all surfaces shall be thoroughly inspected under adequate lighting to determine anchor pattern, quality of blasting and identify any surface defects prior to coating application. All surface defects such as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations, slugs or any other defects considered Injurious to the coating Integrity made visible during blast cleaning shall be reported to the COMPANY Representative and on permission from COMPANY Representative, such defects shall be removed by filing or grinding. After any grinding or mechanical repairs, the remaining wall thickness shall be checked and compared with specified thickness. Any pipes having thickness less than 95% of specified thickness shall be kept aside and disposed off as per the instructions of COMPANY Representative. The method employed to remove surface defects shall not burnish or destroy the anchor pattern or contaminate the surface. Pneumatic tools shall not be used unless they are fitted with effective air/oil and water traps. Where burnishing results in destruction of anchor pattern, the anchor pattern shall be restored by suitable means. Pipes which have damages repaired by grinding and have ground areas more than 50mm in diameter shall be re-blasted. Any dust or loose residues that have been accumulated during blasting and/or during filing/grinding operations shall be removed by vacuum cleaning. If contamination of surface occurs, the quality of blast cleaning method and process shall be examined. If the surface roughness is outside the specified limit, the blast cleaning material shall be checked and replaced.
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8.9

8.10

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8.11

Upon Completion of the blasting operations, the quality control supervisor shall accept the pipe for further processing or return for re-blasting after removal of defects/imperfections. In case imperfections are considered detrimental to the coating quality, the same shall be reported to COMPANY'S Representative for final decision on rejection or re-blasting / removal of defects. Re-blasting / removal of defects or returning pipe to the yard shall be at the CONTRACTOR'S cost. COMPANY'S Representative, in additions, reserves the right to initiate any of the above actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal finish, etc.

8.12

In order to ensure that pipe with defects are not processed further, provisions shall be available to lift the pipes from inspection stand. Chemical Pre-treatment with Chromate Solution Following completion of abrasive blast cleaning, all pipe surface shall be chemically pre-treated with a10% strength chromate solution. The CONTRACTOR shall provide data sheets and supporting documentation for the chemical to be used. The documentation shall verify that the chemical is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification. The chemical pre-treatment shall be applied fully in accordance with the chemical suppliers' Instructions and in a manner that ensures 100% uniform coverage of the pipe surface without introducing surface contamination.

8.13 8.13.1 8.13.2

8.13.3

8.13.4 The CONTRACTOR shall check that the concentration of the chemical pre- treatment solution remains within the range recommended by the chemical manufacturer for the pipe coating process. The concentration shall be checked at the make up of each fresh solution and once per hour, using a method approved by the chemical manufacturer. The CONTRACTOR shall also ensure that the chemical pre-treatment solution remains free from contamination at all times. Recycling of chemical pretreatment solution is not permitted. 8.13.5 The CONTRACTOR shall ensure that the temperature of the substrate is maintained between 40C and 80C and the chromate solution temperature does not exceed 60C or as recommended by the manufacturer. The chromate coating shall be smooth, even, free from runs, drips or excessive application and lightly adherent with no flaking of the coating. The chromate coated steel must be thoroughly dried immediately after application and shall be achieved by boiling off any residual solution on the surface. The total allowable elapsed time between completion of the blasting operations and commencement of the pre-coating and heating operations shall be such that no detectable oxidation of the surface occurs. Relative humidity readings shall be recorded every half an hour during the blasting operations in the immediate vicinity of the operations. The maximum elapsed time shall not exceed the duration given
3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE) DOCUMENT No. S-04-02-005 REV-0 Page 20 of 34

8.13.6

8.14

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below:

Relative Humidity % >80 70 to 80 <70

Maximum elapsed time 2 hours 3 hours 4 hours

Any pipe not processed within the above time-humidity requirement shall be completely re-blasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions have not been exceeded. 8.15 Pipe handling between abrasive blasting and pipe coating shall not damage the surface profile achieved during blasting. Any pipe affected by the damage to the surface exceeding 200mm2 in area and/or having contamination of steel surface shall be rejected and sent for re-blasting. COATING APPLICATION The external surface of the cleaned pipe conforming to clause 8.0 of this specification shall be immediately coated with 3-layer extruded polyethylene coating in accordance with the procedures approved by COMPANY, relevant standards and this specification. In general the procedure shall be as follows: 9.1 9 1.1 Pipe Heating Immediately prior to heating of pipe, all dust and grit shall be removed from inside of the pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be made to protect the bevel ends from getting damaged during the coating operation. Induction heater or gas fired heating shall be used for heating the pipe. The method shall be capable of maintaining uniform temperature along the total length of the pipe, and shall be such that it shall not contaminate the surface to be coated. In case of induction heating, appropriate frequency shall be used to ensure 'deep heating' and intense skin heating is avoided. Gas fired heating system shall be well adjusted so that no combustion products are deposited on the steel surface. This shall be demonstrated on bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating (In the form of blueing or other apparent oxide formation) is not acceptable. External surface of the pipe shall be heated to about 190Cor within a temperature range (min. to max.) as recommended by the powder manufacturer. Required pipe temperature shall be maintained as it enters the coating chamber. Temperature of the pipe surface shall be continuously monitored & recorded by using suitable Instruments such as infrared sensors, contact thermometers,
3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE) DOCUMENT No. S-04-02-005 REV-0 Page 21 of 34

9.0

9.1.2

9.1.3

9.1.4

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Copyright GAIL All rights reserved

thermocouples etc. The recording method shall allow to correlate each line pipe. The monitoring instrument shall be able to raise an alarm/activate audio system (hooter) in the event of tripping of induction heater/gas fired heater or in the event of pipe temperature being outside the range recommended by the manufacturer. Any deviation from the application temperature range recommended by manufacturer shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of temperature deviation shall be identified by marking and rejected. Such rejected pipes shall be stripped, re-cleaned and recoated. 9.1.5 9.1.6 Temperature measuring & monitoring equipment shall be calibrated twice every shift and/or as per COMPANY Representative's instruction. CONTRACTOR shall ensure that pipe surface emissivity variations are minimized during pipe heating. To avoid significant variance, more than once blasted joints should be coated at the same time and not mixed with joints blasted only once. Pipe Coating Subsequent to pipe heating, coating consisting of following layers shall be applied onto the pipe. i. Electrostatic application of epoxy powder of minimum dry film thickness 0.150 mm, unless otherwise specified. The maximum thickness shall not exceed the epoxy thickness specified by epoxy powder manufacturer. Grafted co-polymer adhesive application by extrusion, minimum thickness 0.200 mm. Polyethylene application by extrusion.

9.2 9.2.1

ii. iii.

The coated pipe shall be subsequently quenched and cooled in water for a period that shall sufficiently lower the temperature of pipe coating to permit handling and inspection. 9.2.2 Minimum total thickness of finished coating shall be as under: Pipe Size (Specified Outside Diameter) Minimum Coating Thickness (mm)(*) Normal Type (n) Up to 10 " (273.1 mm) Over l0 (273.1 mm) to below 20" (508.0 mm) From 20" (508.0mm) to below 32" (813.0 mm)
GAIL (INDIA) LTD NEW DELHI 3-LAYER POLYETHYLENE COATING OF LINEPIPES (ONSHORE)

Reinforced Type (v) 2.7 2.9 3.2


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2.0 2.2 2.5


DOCUMENT No. S-04-02-005

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From 32" (813.0 mm) and above

3.0

3.7

(*) In case HDPE material is used as top coat, 10% reduction in minimum coating thickness specified is permissible. Required coating thickness shall be Normal Type (n), unless otherwise specified. 9.2.3 Coating materials shall be inspected in accordance with the manufacturer's recommendation prior to coating application and it shall be ensured that the materials are moisture free. In case the relative humidity exceeds 80%, the adhesive and polyethylene material shall be dried using hot dry air as per the directions of COMPANY Representative. Prior to starting the application of fusion bonded epoxy powder, the recovery system shall be thoroughly cleaned to remove any unused powder remaining from a previous line pipe coating application. The use of recycled powder shall be permitted subject to: a. Satisfactory qualification of the reclaimed system during PQT stage b. The proportion of the reclaimed powder in the working mix does not exceed 20% at any one time. c. The quality of the recycled powder being routinely checked during production, at a minimum frequency of once per shift and consistently meets the requirements stated at para 5.3.1 9.2.5 Dry air, free of oil and moisture shall be used in the coating chamber and spraying system and filters, dehumidifier/dryer as required along with control & monitoring system shall be provided for this purpose. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be at least (-) 40C and this shall be monitored during the regular production. Air pressure in the epoxy spray guns shall be controlled, continuously monitored and recorded by using suitable instruments. The air pressure shall be controlled within the limits established during coating procedure qualification. The monitoring system shall be capable of rising an alarm activate audio system (hooter) in the event of change in air pressure beyond the set limits. Any deviation from the pre-set limits shall be rectified, if immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of air pressure deviation shall be identified by suitable marking and rejected. Such rejected pipes shall be stripped and recoated. Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed and within the window recommended by the manufacturer. The CONTRACTOR shall establish, to the satisfaction of the COMPANY Representative, that the adhesive is applied within the gel time window of epoxy and at the temperature recommended by the adhesive manufacturer. The CONTRACTOR shall state the minimum and maximum time interval between epoxy and adhesive application at the proposed pre-heat temperature and line speed.
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9.2.4

9.2.6

9.2.7

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9.2.8

Extruded polyethylene layer shall be applied over the adhesive layer within the time limit established during PQT stage and within the time/temperature range recommended by the manufacturer. The extrusion temperatures of the adhesive and polyethylene shall be continuously recorded. The monitoring instruments shall be independent of the temperature control equipment. The instruments shall be calibrated prior to start of each shift. CONTRACTOR shall ensure that there is no entrapment of air or void formation along the seam weld (where applicable) during application of coating. Air entrapment below the coating and also along the coating overlap shall be prevented by forcing the coating on to the pipe using high pressure roller of suitable design during coating application. In case it is not adequately achieved, CONTRACTOR shall supplement by other methods to avoid air entrapment. The methods used shall be witnessed and approved by COMPANY. Resultant coating shall have a uniform gloss and appearance and shall be free from air bubbles, wrinkles, holidays, irregularities, discontinuities, separation between layers of polyethylene & adhesive, etc. Coating and/or adhesive shall terminate 150 mm (+) 20 / (-) 0 mm from pipe end. The adhesive shall seal the end of applied coating. CONTRACTOR shall adopt mechanical brushing for termination of the coating at pipe ends. Edge of the coating shall be shaped to form a bevel angle of 30 to 45. Failure to comply with any of the above applicable requirement and of the approved procedure shall be cause for the rejection of the coating and such coating shall be removed in a manner approved by COMPANY at CONTRACTOR's expense. INSPECTION AND TESTING General The CONTRACTOR shall establish and maintain such quality assurance system as are necessary to ensure that goods or services supplied comply in all respects with the requirements of this specification. The minimum inspection and testing to be performed shall be as indicated subsequently herein.

9.2.9

9.2.10

9.2.11

9.2.12

10.0 10.1

10.2

Visual Inspection Immediately following the coating, each coated pipe shall be visually checked for imperfections and irregularities of the coating. The coating shall be of natural colour and gloss, smooth and uniform and shall be blemish free with no dust or other particulate inclusions. The coating shall not show any defects such as blisters, pinholes, scratches, wrinkles, engravings, cuts, swellings, disbonded zones, air inclusions, tears, voids or any other irregularities. Special attention shall be paid to the areas adjacent to the longitudinal weld (if applicable), adjacent to the cut-back at each end of pipe and within the body of the pipe.

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DOCUMENT No. S-04-02-005

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In addition inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. 10.3 Coating Thickness a. The coating thickness shall be determined by taking at least 10 measurements at locations uniformly distributed over the length and periphery of each pipe. In case of welded pipes, five of the above readings shall be made at the apex of the weld seam, uniformly distributed over the length of the coated pipe. All readings must meet the minimum requirements. However, localized coating thickness of less than the permissible minimum thickness can be tolerated on the condition that it does not attain a total extent of more than 5 cm2 per meter length of coated pipe, and the actual coating thickness does not drop more than 10% below the permissible minimum coating thickness at these locations. The frequency of thickness measurement as stated above shall be initially on every pipe, but may be reduced depending upon consistency of results, at the sole discretion of COMPANY Representative. Results of all measurements shall be recorded. b. Thickness of epoxy and adhesive shall be measured at the beginning of each shift and whenever the plant re-starts after any stoppage for compliance. Coating of epoxy and adhesive on portion of pipe required for this purpose, stripping and recoating of such partly coated pipes shall be at CONTRACTOR's expense. c. Coated pipes not meeting the above requirements shall be rejected. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR's expense. 10.4 Holiday Detection a. Each coated pipe length shall be checked over 100% of coated surface by means of a "holiday detector" of a type approved by COMPANY for detecting holidays in the finished coating. b. The holiday detector shall be a low pulse D.C. full circle electronic detector with audible alarm and precise voltage control complying with DIN VDE 0433 Part 2. The set voltage for inspection shall be minimum 25 kV. Travel speed shall not exceed 300 mm/s. c. CONTRACTOR shall calibrate the holiday detector at least once every 4 hours of production. CONTRACTOR shall have necessary instruments or devices for calibrating the holiday detector. d. Any pipe coating shall be rejected if more than 1(one) holiday & area more than 100 cm2 in size are detected in its length attributable to coating process.

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DOCUMENT No. S-04-02-005

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e. Holidays which are lesser in size than those mentioned in (d) above, shall be repaired in accordance with an approved procedure and shall be at CONTRACTOR's expense. 10.5 Bond Strength Test a. CONTRACTOR shall conduct bond strength test for composite coating as per Clause 5.3.3(a) of this specification. A minimum of 65 mm length shall be peeled. First 20 mm and last 20 mm shall not be counted for assessment of bond strength. b. The frequency of test for cut back portions shall be one pipe in every fifteen (15) pipes coated and for middle of pipe shall be one pipe in every sixty (60) pipes coated or one pipe per shift whichever is higher. On each selected pipe, bond strength shall be performed for each specified temperature. Test shall be performed at each cut back portion and one in the middle of pipe. The system shall disbond /separate cohesively either in adhesive layer or in polyethylene layer. Majority of the peeled off area on the pipe shall show presence of adhesive. Disbondment / separation at epoxy to steel interface or epoxy / adhesive interface or adhesive / polyethylene interface shall not be permitted. The failure mode shall be recorded for each test. c. In case the test fails to comply with the specified requirement, the CONTRACTOR shall test the preceding and succeeding coated pipe. If both pipes pass the test, then the remainder of the pipe joints in that shift shall be deemed satisfactory. If either pipe fails to meet the specified requirements, all pipes coated during that shift shall be tested until the coating is proved acceptable. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR'S expense. d. The frequency of bond strength test as per para 10.5 (b) for cut back portion may be reduced depending upon the consistency of result to one pipe in every twenty five (25) instead of every fifteen pipes, at the sole discretion of the COMPANY Representative. 10.6 Impact Strength a. Impact strength test shall be conducted as per clause 5.3.3(b) of this specification. Initially the frequency of test shall be two (2) coated pipes per shift that may be further reduced to one coated pipe per 2 weeks depending upon consistently acceptable results at the sole discretion of COMPANY'S Representative. b. Minimum thirty (30) impacts located equidistant along the length of coated pipe shall be performed. c. Immediately after testing, the test area shall be subjected to holiday detection at the same voltage as used prior to impact strength test. The pipe shall be rejected if any holiday is noted in the test area. d. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above. 10.7 Indentation Hardness a. Indentation hardness test shall be as per clause 5.3.3 (c) of this specification. The frequency of test shall be initially 2 (two) coated pipes per shift which shall be further
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reduced to one test each on 2 coated pipes per week at random after 1 week of consistently acceptable results. Two samples for each temperature shall be taken from the cut back portion of coated pipe and one in the middle of the pipe for this test. b. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above. 10.8 Air Entrapment Test a. Strips from bond strength tests or coated pipe may be used to help determine the porosity of the finished coating. Strip shall be also cut from longitudinal weld (if applicable) at cut back portion and examined for the presence of voids. b. Bond strength strip shall be viewed from the side and at the failure interface. At the pipe bond strength test location, utility knife shall be used to cut the edge of the coating to a 45 angle and view with a microscope. Similar examination shall be done in the coating cut back area. c. One sample each either on the bond strength strip or coated pipe and strip cut from the longitudinal weld (if applicable) shall be examined for air entrapment per shift. Strips shall be viewed from the side. d. All examination shall done using a 30X magnification hand-held microscope. The polyethylene and adhesive layers shall have no more than 10% of the observed area taken up with air entrapment (porosity or bubbles). Air entrapment shall not occupy more than 10% of the thickness in each case. Bubbles shall not link together to provide a moisture path to the epoxy layer. e. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.5 (c) above. 10.9 Degree of Cure Epoxy film samples shall be removed from cut back portion of the coated pipe using hammer and cold chisel and the samples shall be taken for cure test using DSC procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (Tg) and % cure (H) shall comply with the specified requirements. a. Frequency of this test shall be once per shift. Pipe shall be selected randomly by COMPANY Representative during the middle of a shift. Suitable provisions / arrangements as per the instructions of COMPANY Representative shall be made by the CONTRACTOR for this purpose b. In case of test failure, production carried out during the entire shift shall be rejected, unless the CONTRACTOR proposes a method to establish the compliance with the degree of cure requirements of all pipes coated during that shift. 10.10 Epoxy Layer Adhesion Test

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a. Adhesion of epoxy layer shall be determined at ambient temperature by the "St Andrews Cross" method i.e. by cutting two straight lines through the epoxy layer with a sharp knife. The incisions shall intersect at an angle of 30V1500. The epoxy coating shall resist disbondment from the steel when attempts are made to flick/lift the coating from the 30 angle with a sharp knife. b. Frequency of this test shall be once per shift. The test shall be carried out at the cut hack portion on the pipe from which the Degree of Cure test has been carried out as per para 10.9 above. c. In case of test failure, retesting and disposal of coated pipe shall be as per para 10.9 (c) above. 10.11 Cathodic Dlsbondment Test a. 48 hours CD test shall be conducted as per clause 5.3.3 (h) of this specification. b. The frequency of this test shall be once in every two weeks or one test representing each batch of epoxy powder used, whichever is more frequent. c. In case the test fails to conform to the specified requirement, at the option of the CONTRACTOR, all pipes coated after the previous acceptable test and prior to next acceptable test shall be rejected or the test shall be repeated using two additional samples taken from the same end of the affected pipe. When both retests conform to the specified requirement, the lot of pipes shall be accepted. When one or both the retests fail to conform to the specified requirement, all coated pipes after previous acceptable test and prior to next acceptable shall be rejected. All rejected pipes shall be stripped, re-cleaned and re-coated. COMPANY may consider a further retest program to determine whether any of the affected pipe meet the criteria for acceptance upon written request by the CONTRACTOR. 10.12. Damages occurring to pipe coating during above tests shall be repaired in accordance with approved coating repair procedure. 10.13 10.14 Repairs occurring on account of the production tests are however excluded from above mentioned limitations at para 10.4 (d) above. COMPANY reserve the right to perform inspection and witness tests on all activities concerning the pipe coating operations starting from bare pipe to finished coated pipe ready for dispatch and also testing of raw materials. CONTRACTOR shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection to the COMPANY's representative. Inspection and tests performed or witnessed by COMPANY's representative shall in no way relieve the contractors obligation to perform the required inspection and tests. In case rate of defective or rejected pipes and/or samples tests are 10% or more for a single shift (typically 8 hours), CONTRACTOR shall be required to stop production and carry out a full and detailed investigation and shall submit findings to COMPANY for approval. CONTRACTOR shall recommence the production only after getting the written permission from COMPANY. Under no circumstances any action or omission of the COMPANY'S Representative shall relieve the CONTRACTOR of his responsibility for material and quality of
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coating produced. No pipes shall be transported from the coating plant unless authorized by COMPANY in writing. 11.0 11.1 HANDLING, TRANSPORTATION AND STORAGE The CONTRACTOR shall be fully responsible for the pipe and for the pipe identification marking from the time of "taking over" of bare pipe from COMPANY until such time that the coated line pipes are 'handed over and/or installed in the permanent installation as the case may be according to the provisions of the CONTRACT. At the time of "taking over" of bare pipes CONTRACTOR shall inspect and record all the relevant details referred above including pipe defects in the presence of COMPANY. All pipes shall be checked for bevel damages, weld seam height, dents, gouges, corrosion and other damages. COMPANY Representative shall decide whether pipe defects / damages are suitable for repair. Damage to the pipes that occur after the CONTRACTOR has taken delivery such as dents, flats, or damage to the weld ends shall be cut off or removed and pipes re-bevelled and repaired again as necessary. The cost of this work, as well as that of the pipe lost in cutting and repair shall be to the CONTRACTOR'S account. All such works shall be carried out after written approval of the COMPANY. Any reduction in length shall he indicated In the CONTRACTOR'S pipe tracking system. 11.2 The CONTRACTOR shall unload, load, stockpile and transport the bare pipes within the coating plant(s) using suitable means and in a manner to avoid damage to pipes. The CONTRACTOR shall stockpile the bare pipes at the storage area of the coating plant. The CONTRACTOR shall prepare and furnish to COMPANY a procedure/calculation generally in compliance with API RP-5L1 for stacking of pipes of individual sizes, which shall be approved by COMPANY prior to commencement. 11.3 The CONTRACTOR shall load, unload, transport and stockpile the coated pipes within the coating plant using approved suitable means and in a manner to avoid damage to the pipe and coating. The COMPANY shall approve such procedure prior to commencement of work. Coated pipes may be handled by means of slings and belts of proper width (minimum 60 mm) made of non- abrasive/non-metallic materials, in this case, pipes to be stacked shall be separated row by row to avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings is prohibited. Fork lifts may be used provided that the arms of the forklift are covered with suitable pads, preferably rubber. Bare/ coated pipes at all times shall be stacked completely clear from the ground, at least 300 mm, so that the bottom row of pipes remain free from any surface water. The pipes shall be stacked at a slope so that driving rain does not collect inside the pipe. Bare / coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with suitable cover. This cover can be of dry, germ free straw covered with plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of the pipes.
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Stacks shall consist of limited number of layers such that the pressure exercised by the pipe's own weight does not cause damages to the coating. CONTRACTOR shall submit calculations for COMPANY approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld seam of pipes shall be positioned always in a manner so as not to touch the adjacent pipes. The ends of the pipes during handling and stacking shall always be protected with bevel protectors. 11.6 The lorries used for transportation shall be equipped with adequate pipe supports having as many round hollow beds as there are pipes to be placed on the bottom of the lorry bed. Total width of the supports shall be at least 5% of the pipe length and min. 3 no. support shall be provided. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection must be free from all nails and staples where pipes are in contact. The second layer and all following layers shall be separated from the other with adequate number of separating layers of protective material such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of lorries used for transportation shall be covered by non-abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated surface. Slings or non-metallic straps shall be used for securing loads during transportation. They shall be suitably padded at the contact points with the pipe 11.7 Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially due to humidity, exposure to high thermal excursions or other adverse weather conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced at CONTRACTOR's expenses. These materials shall always be handled during loading, unloading and storage in a manner so as to prevent any damage, alteration and dispersion. When supplied in containers and envelopes, they shall not be dropped or thrown, or removed by means of hooks, both during the handling operations till their complete use. During unloading, transport and utilization, any contact with water, earth, crushed stone and any other foreign material shall be carefully avoided. CONTRACTOR shall strictly follow Manufacturer's instructions regarding storage temperature and methods for volatile materials that are susceptible to change in properties and characteristics due to unsuitable storage. If necessary the CONTRACTOR shall provide for a proper conditioning. 11.8 In case of any marine transportation of bare/coated line pipes involved, the same shall be carried out in compliance with API RP 5LW. CONTRACTOR shall furnish all details pertaining to marine transportation including drawings of cargo barges, storing/stacking, sea fastening of pipes on the barges/marine vessels to the company for approval prior to undertaking such transportation works. In addition
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contractor shall also carry out requisite analyses considering the proposed transportation scheme and establish the same is safe and stable. On-deck overseas shipment shall not be allowed. 12.0 REPAIR OF COATING CONTRACTOR shall submit to COMPANY, its methods and materials proposed to be used for executing a coating repair and shall receive approval from COMPANY prior to use. In open storage the repair coating materials must be able to withstand a temperature of at least (+)80C without impairing its serviceability and properties. CONTRACTOR shall furnish manufacturer's test certificates for the repair materials clearly establishing the compliance of the repair materials with the applicable coating requirements indicated in this specification. All pipes leaving coating plant shall have sound external coating with no holiday or porosity on 100% of the surface. Defects, repairs and acceptability criteria shall be as follows: Pipes showing porosities or very small damage not picked up during holiday test and having a surface less than 0.5 cm3 or linear damage (cut) of less than 3 cm shall be repaired by stick using material of same quality. Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2 mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal. Defects of size exceeding above mentioned area or holidays of width less than 300 mm shall be repaired with heat shrink repair patch by exposing the bare metal surface. Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500 mm shall be repaired using heat shrinkable sleeves of HTLP 80 or equivalent. Pipes with bigger damage shall be stripped and recoated. In case of coating defect close to coating cut back, CONTRACTOR shall remove the coating throughout the entire circumference of the pipe down to the steel surface and increase the coating cut back length. Now if the coating cut back exceeds 170 mm of linear length of pipe then the coating shall be repaired by the use of heat shrink sleeves thereby making up the coating cut back length of 150 mm.

Not withstanding the above, under no circumstances, if the defect exceeds 70 mm from the original coating cut back length, the entire coating shall be removed and the pipe shall be recycled through the entire coating procedure. Irrespective of type of repair, the maximum numbers of repair of coating shall be as follows:
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Holiday repair of size <100 cm2 attributable to process of coating application shall be maximum one number per pipe. In addition to the above, defects to be repaired by heat shrink patch/sleeve shall be maximum 2 (two) per pipe.

Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The above is exclusive of the repairs warranted due to testing as per this specification. All repairs carried out to coating for whatever reason shall be to the account of CONTRACTOR. Cosmetic damages occurring in the polyethylene layer only need not be repaired by exposing up to steel surface, as deemed fit by the COMPANY Representative. In any case the CONTRACTOR shall establish his material, methods and procedure of repair that result in an acceptable quality of product by testing and shall receive approval from COMPANY prior to use. Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coating thickness no less than the parent coating thickness. CONTRACTOR shall test repairs to coating as and when required by COMPANY. 13.0 MARKING CONTRACTOR shall place marking on the outside surface of the coating at one end of the coated pipe, and marking snail indicate, but not limited to the following information: a. Pipe number, Heat number b. Diameter & Wall thickness c. Coated pipe number d. Colour band e. Any other information considered relevant by COMPANY. f. Pipe Manufacturer Name g. Inspection Mark/Punch CONTRACTOR shall obtain prior approval on marking procedure to be adopted from the COMPANY. 14.0 14.1 QUALITY ASSURANCE The CONTRACTOR shall have established within his organization and, shall operate for the contract, a documented Quality System that ensures that the requirements of this specification are met in all aspects. The Quality System shall be based upon ISO 9001/2 or equivalent. The CONTRACTOR shall have established a Quality Assurance Group within its
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organization that shall be responsible for reviewing the Quality System and ensuring that it is implemented. 14.3 14.4 The CONTRACTOR shall submit the procedures that comprise the Quality System to the COMPANY for agreement. The CONTRACTOR'S Quality System shall pay particular attention to the control of Suppliers and Sub-contractors and shall ensure that the requirements of this specification are satisfied by the Suppliers and Sub contractors operating Quality system in their organization. The CONTRACTOR shall, prior to the commencement of work, prepare and issue a Quality Plan for all of the activities required to satisfy the requirements of this specification. The plan shall include any sub-contracted work, for which the subcontractors Quality Plans shall be submitted. The plan shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality control, inspection, testing and certification activities with reference to the relevant procedures and the acceptance standards. The CONTRACTOR'S Quality system and associated procedures may, with due notice, be subject to formal audits. The application of quality control by the CONTRACTOR will be monitored by the COMPANY Representatives who will witness and accept the inspection, testing and associated work required by this specification.

14.5

14.6

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ANNEXURE-I LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS The following combinations of coating materials are considered acceptable. In the event of award of contract, CONTRACTOR shall furnish the combination(s) proposed and re-confirmation of compatibility & properties of the proposed combination (s) from the raw materials Manufacturers & system properties. Epoxy Powder (Manufacturer) CORRO-COAT EP-F2001 (JOTUN) PE 50-8190/8191 (BASF) or CORRO-COAT EP-F 2001 (JOTUN) PE 50-6109 (BASF) or CORRO-COAT EP-F 2001/2002HW (JOTUN) or SCOTCHKOTE 226N (3M) CORRO-COAT EP-F 2001 (JOTUN) SCOTCHKOTE 226N (3M) LE-149 V (S K CORPORATION) ME 0420 (BOREALIS) ET 509 B (S K CORPORATION) PB 48A004 (GAIL) Adhesive (Manufacturer) FUSABOND158D (DUPONT) LUCALEN G3510H (BASF) ME 0420 (BORALIS) PE Compound (Manufacturer) SCLAIR 35 BP HDPE (NOVACOR) LUPOLEN 3652 D SW 00413 (BASF) HE 3450 (BOREALIS)

Although the above combinations would be acceptable to COMPANY, the responsibility of suitability for application, performance, properties and compliance to the coating system requirements shall unconditionally lie with the CONTRACTOR.

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SPECIFICATION FOR INTERNAL EPOXY COATING FOR LINE PIPES

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SPECIFICATION FOR INTERNAL EPOXY COATING OF LINE PIPES

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CONTENTS 1 2 3 4 5 6 7 8 9 ANNEX A : ANNEX B : ANNEX C : ANNEX D : ANNEX E : SCOPE DEFINITIONS ABBREVIATIONS INTERNAL LIQUID EPOXY COATING COATING MATERIAL APPLICATION OF THE COATING MATERIAL PRODUCTION CONTROL REPAIRS HANDLING, TRANSPORTATION AND STORAGE (NORMATIVE) DETERMINATION OF ASH (REFER TO SUB CLAUSE 5.2.5) (NORMATIVE) DRY FILM THICKNESS (REFER TO SUB CLAUSE 5.3.3 AND 7.1.2) (NORMATIVE) RESISTANCE TO GAS PRESSURE VARIATION (REFER TO SUB CLAUSE 5.3.9) (NORMATIVE) HYDRAULIC- PRESSURE BLISTERING (REFER TO SUB CLAUSE 5.3.12) (NORMATIVE) POROSITY OF A FILM OF THE COATING MATERIAL ON A GLASS PANEL (REFER TO SUB CLAUSE 7.2.6) (NORMATIVE) CURING TEST (REFER TO SUB CLAUSE 7.2.5) (NORMATIVE) WET-SPONGE TEST (REFER TO SUB CLAUSE 7.2.6)

ANNEX F : ANNEX G :

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1. SCOPE The intent of this specification is to set forth the minimum requirements for supply / arrangement of all materials, plant, equipments, plant sites consumables, utilities and application including all labour, supervision, inspection & test etc for application of internal epoxy coating. 2. DEFINITIONS OWNER means the GAIL (INDIA) LIMITED The COATING CONTRACTOR is the party, who will do coating, supplies equipment and services to perform the duties specified by the contractor CONTRACTOR / VENDOR means the person(s) named as contractor in the FORM OF AGREEMENT and the legal successors in title to this person (s). The word shall indicates a requirement The word should indicates a recommendation 3. ABBREVIATIONS ASTM - American Society for Testing and Materials BS DIN FBE ISO NACE - British Standards - Deutsche Industries Normen - Fusion Bonded Epoxy - International Organisation of Standardisation - National Association of Corrosion Engineers

SSPC - Steel Structures Painting Council 3.1. Codes, Regulations and Standards The latest edition of the following codes and standards shall establish the minimum standards for the work. VENDOR may use alternate standards that meet or exceed those if approved by OWNER. American Society for Testing and Materials (ASTM) - ASTM D 638 Test Methods for Tensile Properties of Plastics
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- ASTM G95

Test Method for Cathodic Disbonding of Pipeline Coatings.

International Standards Organization (ISO) - ISO 9002 Quality System Quality Assurance in Production, Installation and Servicing - ISO 8501-1 Preparation of Steel Substrates before Application of (Part I) Paints and Related Products Visual Assessment of Surface Cleanliness - ISO 8503-1 Preparation of Steel Substrates before Application of (Part 1) Paints and Related Products Visual Assessment of Surface Cleanliness - ISO 15741 Paints and Varnishes Friction-reduction coatings for the interior of onshore and offshore steel pipeline for non-corrosive gases. British Standards (BS) - BS 5750 : Specification for Final Inspection and Testing (Part 3)

Deutsche Institute Fur Normung (DIN) - DIN 30670 - DIN 50049 3.4. : Polyethylene Coatings for Steel Pipes and Fittings : Inspection Documents for the Delivery of Metallic Products.

Document Precedence

The VENDOR shall notify OWNER / CONSULTANT of any conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and / or interpretation precedence shall be obtained from OWNER / CONSULTANT in writing before proceeding with the design & manufacture. In case of conflict, the order of precedence shall be: Coating Data Sheets Coating Narrative Specification Design General Specification and Standards Industry Codes and Standards

4. INTERNAL LIQUID EPOXY COATING Each pipeline shall be provided with an internal liquid epoxy coating by the Vendor. The internal coating shall be as per ISO 15741 2001 (E). 5. COATING MATERIAL
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5.1. General The coating material shall typically be a two-pack epoxy paint. It shall not contain any substances which will be released from the paint film after it has cured and are proven to be detrimental to the operation of the pipeline and the quality of the gas. Unless otherwise agreed, the coating material shall be qualified in accordance with 5.2 and 5.3 and shall not be changed after qualification. The manufacturer of the coating material shall provide on request infrared spectrograms of the base component and the curing agent component (see 5.2.8) In addition, the manufacturer shall provide a product data sheet (see 5.6), a health and safety data sheet and a certificate stating the test results obtained in accordance with 5.2 and 5.3 respectively and, if applicable, deviating test conditions. The manufacturer shall also provide with every batch of the coating material a batch test certificate stating the information as given in 5.8. Unless otherwise agreed, the applied coating shall provide corrosion protection during storage and transport for a minimum period of one year without significant breakdown of the coating. The typical operating-temperature range for this type of coating is between -200C and 110 0C. Where, subsequently, external coatings have to be applied, care shall be taken not to allow the internal coating to be damaged by the elevated temperatures which may occur. 5.2. Particular requirement for qualification of the coating material

5.2.1. General The following sub clauses describe the laboratory test methods which are required for qualification of the coating material. 5.2.2. Non-volatile matter (by mass) When determined in accordance with ISO 3251, the non-volatile matter (by mass) of the coating material shall comply with the value specified by the coating material manufacturer in the qualification certificate (Table- 2) 5.2.3. Non-volatile matter (by volume)
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When determined in accordance with ISO 3233, the non-volatile matter (by volume) of the coating material shall comply with the value specified by the coating material manufacturer in the product data sheet (Table-1) 5.2.4. Viscosity When determined by the method specified by the manufacturer, the viscosity of the ready-mixed coating material shall comply with the value specified by the coating material manufacturer in the qualification certificate (Table 2) The viscosity should preferably be measured with ISO 2431 5.2.5. Density When determined in accordance with one of the parts of ISO 2811, the density of the coating material shall comply with the value specified by the coating material manufacturer in the product data sheet (Table 1) 5.2.6. Ash (residue on ignition) When determined in accordance with the method described in annex A, the ash (residue on ignition) of the coating material shall comply with the value specified by the coating material manufacturer in the qualification certificates (Table 2) 5.2.7. Pot life The pot life is considered to be the time taken by the ready-mixed coating material to reach a condition at which it can no longer be applied satisfactorily. The pot life shall be specified in the product data sheet (see 5.6) 5.2.8. Infrared spectrograms Infrared spectrograms of the base component and the curing agent component shall be submitted on request. 5.2.9. Appearance The appearance and continuity of the coating shall be inspected visually without any magnification. 5.3. Particular requirement for qualifications of the cured paint film

5.3.1. Preparation of test panels


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Perform the tests specified in 5.3.3 to 5.3.12 on coatings applied to the required dry film thickness specified in 5.3.3 by spraying on to test panels (steel or glass). Prepare steel test panels as specified in 6.2 and glass panels as specified each test at least in duplicate. 5.3.2. Conditions of test panels If specified, condition the coated test panels using one of the following cycles, depending on the substrate and on the individuals test. Cycle B and cycle C are optional and the choice of the conditioning cycle depends on the time available to perform the test procedure. Cycle A Substrate: Steel or Glass - Condition at 18 0C to 25 0C and 80% relative humidity until the coating is at least tack-free. - Dry for 30 minutes in a circulating-air oven at (75+2)0C - Condition for a minimum of 30 minutes at 180C to 250C and 80% relative humidity before testing. Cycle B Substrate: Steel or Glass - condition at 180C to 250C and 80% relative humidity until the coating is at least tack-free. - Dry for 30 minutes in a circulating-air oven at (150+2)0C - Condition for a minimum of 30 minutes at 18OC to 25OC and 80% relative humidity before testing. Cycle C Substrate: Steel or Glass - condition at 18OC to 25OC and 80% relative humidity until the coating is at least tack-free. - Dry for 30 minutes in a circulating-air oven at (40+2) OC. - Condition for a minimum of 30 minutes at 18OC to 25OC and 80% relative humidity before testing.
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5.3.3.

Dry film thickness Unless otherwise agreed, the dry film thickness of the coating, applied on a glass or steel panel, shall be between 60 m and 100 m except for the test described in 5.3.6 (resistance to neutral salt spray). Unless otherwise agreed, the dry film thickness shall be measured in accordance with ISO 2808: 1997, Method No. 2 for glass and Method No. 10 for blast-cleaned steel, following the procedure given in annex B.

5.3.4. Adhesion When determined in accordance with ISO 2409, the cross-cut classification of the coating applied on steel panels and conditioned using cycle B or C (see 5.3.2) shall be equal to or lower than 1. 53.5. Buchholz hardness When determined in accordance with ISO 2815, the Buchholz hardness of the coating, applied on glass or steel panels and conditioned using cycle B or C (see 5.3.2) shall have a value of 94 or more. 5.3.6. Resistance to neutral salt spray The coating, applied on steel panels with a dry film thickness of 60 m to 75 m, conditioned using cycle B or C (see 5.3.2), and with an X-cut down to the substrate at least 20 mm from any edge, shall be tested in accordance with ISO 7253 for 480 h. After the test, allow the test panels to dry for at least 30 min at 18OC to 25OC and 80% relative humidity. The coating shall be free from any signs of deterioration, for example blistering (except in the area within 2.0 mm from the X-cut), cracking and staining. Any corrosion shall extend not more than 2.0 mm at the most from the X-cut. It shall not be possible to remove by means of clear plastic tape more than 3.0 mm of the coating in any direction from the area around the X-cut. 5.3.7. Resistance to artificial ageing Prepare two different sets of coated test panels, each set consisting of 3 steel panels. The dimensions of the panels shall be approx. 100 mm X 50 mm X 0.8 mm. Carry out the following procedure: - Condition set 1 using cycle C (see 5.3.2)
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- Condition set 2 using cycle C (see 5.3.2) and then age the panel 80OC in a circulatingair oven for 100 h followed by conditioning for 24 h at 18OC to 25OC and 80% relative humidity. - After ageing, subject the test panels to a bend test in accordance with 5.3.8 The result of the bend test shall comply with the requirement specified in 5.3.8. 5.3.8. Bend test (conical mandrel) Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panel are tested in accordance with ISO 6860, the maximum extent of cracking along the panel from the small and of the mandrel shall be less than or equal to 13 mm, and there shall be no loss of adhesion. 5.3.9. Resistance to gas pressure variations Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panels are tested with annex C, they shall have a generally good appearance when examined in accordance with 5.2.9 and shall not show any blistering. The adhesion value shall fulfill the requirements given in 5.3.4 after conditioning for 24 h and 40 h at 18 OC to 25OC and 80% relative humidity. 5.3.10. Resistance to water immersion Prepare steel panels and conditions them using cycle B or C (see 5.3.2). When the panels are tested in accordance with ISO 2812 2 for 480 h, the coating shall not show any blistering or appreciable softening. The examination shall be carried out 3 min after the panels have been removed from the test liquid. 5.3.11. Resistance to chemicals Prepare steel panels and condition then using cycle B or C (see 5.3.2). When the panels are tested in accordance with ISO 2812-1:1993, Method No. 1, Procedure a, for 168 h, the coating shall not show any blistering or appreciable softening. Use the following test liquid: cyclo hexane; 95% by volume di-ethylene glycol solution in water; hexane; methanol; toluene and lubricating oil (e.g. compressor shall oil in accordance with ISO 6743-4). The test panels shall be completely immersed in the test liquid. The examination shall be carried out at 18 0C to 25 0C and 80% relative humidity 3 min after the panels have been removed from the test liquid. After conditioning for 24 h at 18 0C to 25 0C and 80% relative humidity, the adhesion value shall fulfill the requirements given in 4.3.4. A change in the colour of the coating shall not be
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considered as an indication of inferior coating quality. 5.3.12 Resistance to hydraulic blistering Prepare steel panels and condition them using cycle B or C (see 5.3.2). When the panels are tested in accordance with annex D, the coating shall not show any blistering. The examination shall be carried out at 18 0C to 25 0C and 80% relative humidity 3 min after the panels have been removed from the test liquid. The adhesion value shall fulfil the requirements given in 5.3.4 after conditioning at 18 0 C to 25 0C and 80% relative humidity for 24 h. 5.4. Packaging, labeling and storing All coating materials and solvents shall be stored in the original container bearing the manufacturers label and instruction. At least the following information shall be shown on the label: - The name of the coating material; - The name of the manufacturer of the coating material; - The colour of the coating material; - The batch number; - Instructions and warnings regarding health, safety and environmental protection; - a reference to the relevant product data sheet; 5.5. Quality Assurance It necessary to ensure that the goods or services supplied comply in all respects with the requirements of this International Standard. The coater shall therefore set up and maintain a quality assurance system as, for example, detailed in ISO 9001. The purchaser shall have the right to undertake inspection and testing of the coated goods during any stage of coating at which the quality of the finished goods may be affected and to undertake inspection or testing of coating materials, or other materials used, to ensure compliance with the requirement given in 5.2 and 5.3. 5.6. Product data sheet
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The coating material manufacturers product data sheet give information regarding at least the items listed in Table 1. Table 1 Minimum information to be included in product data sheet Date of issue Name of coating material Name of coating material manufacturer Colour of coating material Type of coating material Shelf life Non-volatile matter by volume a method used (see5.3.2) Density b Test method used (see 5.2.5) Pot life a (see 5.2.7) Flash point c Time to complete curing Recommended thinner Maximum allowed quantity of thinner, in % Recommended surface preparation grade Recommended method of application Recommended maximum / minimum dry film thickness of the applied coating Recommended cleaning solvent (for the application equivalent) Test

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Recommended application conditions (air and steel temperature and relative humidity) Recommended minimum curing conditions Recommended maximum / minimum service temperature Recommended storage conditions Reference to instruction and warnings regarding health, safety and environmental protection Theoretical spreading rate (l/m2 or kg/m2) for a given dry film thickness. a. Only for the mixed coating material. b. Give separately for base component and curing agent component (if pigmented) c. Give separately for base component, curing agent component and mixed coating material. 5.7. Qualification certificate The qualification certificate shall give, as a minimum, the values of the properties listed in Table 2. Table 2 Minimum information to be included in qualification certificate Date of issue Name of coating material Name of coating material manufacturer Authority of issue Property Non-volatile matter by mass a Ash b Viscosity c
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Test method ISO 3251 Annex A

Sub clause See 5.2.2 See 5.2.6 See 5.2.4


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Adhesion Buchholz hardness Resistance to neutral salt spray Resistance to artificial ageing Bend test (conical mandrel) Resistance to gas pressure variations Resistance to water immersion Resistance to chemicals - Resistance to cyclohexane

ISO 2409 ISO 2815 ISO 7253

See 5.3.4 See 5.3.5 See 5.3.6 See 5.3.7

ISO 6860 Annex C ISO 2812-2

See 5.3.8 See 5.3.9 See 5.3.10

- Resistance to 95% by volume diethylene glycol solution in water - Resistance to hexane ISO 2812-1 5.3.11 - Resistance to methanol - Resistance to toluene - Resistance to lubricating oil (e.g. compressed seal oil) material Resistance to hydraulic blistering Annex D See 5.3.12 See

a. Separate for base component, curing agent component and mixed coating material. b. Separate for base component and curing agent component (if pigmented). c. Only for the mixed coating 5.8. Batch test certificate The batch test certificate shall give, as a minimum, the information and test results for the items listed in Table 3
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Table 3 Minimum information to be included in batch test certificate Item Test method Information from the coating material manufacturer Test result

Date of issue Batch number Name of coating material Name of coating material manufacturer Production date

Expiry date for use Non-volatile matter by mass base component Non-volatile matter by mass Curing agent component a Viscosity base component Viscosity curing agent component Density base component Density curing agent component Ash base component c Ash- curing agent component c, d
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See 5.2.2 See 5.2.2 b b See 5.2.5 See 5.2.5 See 5.2.6 See 5.2.6
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Infrared spectrogram d, e See 5.2.8 a. The non-volatile matter by mass of the curing agent component shall not be used for any purposes other than batch consistency checks. b. As specified by the coating material manufacturer. c. If required. d. If pigmented. e. Separately for base component and curing agent component.

6. 6.1 6.2

APPLICATION OF THE COATING MATERIAL General During application of the coating material, all steps in the coating process shall be assessed and recorded. The parameters listed in Table 4 shall be included.

Table 4 Minimum items to be checked and recorded during the coating process Items Coating material Name of product Name of manufacturer Batch number Surface condition prior to surface preparation Surface condition after surface preparation Surface cleanliness Surface profile Surface imperfections E.g. dents, laps
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Method Visual examination

Frequency At every change of shift

Acceptance criteria As specified specified

Visual examination

Every pipe

As specified

ISO 8501-1 ISO 8503-2 Visual examination

Twice per shift Twice per shift Every pipe

As specified As specified Subject to agreement

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Wet paint (mixed) Viscosity and temperature Environmental conditions in the painting area Ambient temperature Steel temperature Relative humidity Flash point Cured paint film on pipes Appearance and continuity Dry film thickness Porosity (pinholes) Cured paint film on steel test panels As described in Table 5 Paint film on glass test panels Porosity (pinholes) As specified

Every time paint is mixed and every time painting is interrupted

As specified

Instrumental Instrumental Instrumental instrumental Visual examination ISO 2808:1997, Method 10 Wet-sponge test (annex G)

At every change of shift

As specified

Spot test Twice per shift (a)

No sagging As specified As required

See table 5

Twice per shift

As specified in Table-5

Annex E

At every change of shift

Max. 5 pores

a. The wet sponge test shall be carried out only if the porosity test on glass panels constitutes a failure

6.2.

Surface preparation First check that the surface are free from any foreign matter such as welding flux, welding spatter, salts, oil or grease. If necessary, wash the surfaces with a highpressure jet of fresh water. Removed organic contaminants using detergents or suitable organic solvents. Then blast-clean the surfaces to surface preparation grade Sa 1/2 in accordance with

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ISO8501-1. Removed, using suitable methods, any surface irregularities or imperfections which may have become visible. Check the surface profile. Unless otherwise agreed, it shall be such that R 5 (see ISO 8503-1) is between 25 m and 60 m. During and after blast-cleaning and prior to application of the coating material, the temperature of the steel surface shall be at least 30C above the dew point or the minimum curing temperature given by the coating material manufacturer, whichever is the higher. 6.3. Paint preparation Before removing each component from its container, stir or agitate it until it is homogeneous, using equipment which is capable of homogenizing the entire contents of the container without excessively entraining air into the material. Mix the two components (base component and curing agent component) thoroughly and, if necessary, dilute in accordance with the coating material manufacturers instructions. After the material has been homogenized, it shall be continuously mixed at a slow speed. The mixed paint shall be free of any lumps and pieces of skin. Measure the viscosity in accordance with the method recommended by the manufacturer and record it. Check whether it complies with the value specified by the manufacturer and keep it constant during application procedure. 6.4. Paint application Check the surface to be coated to see whether it still complies with the specified surface preparation grade and profile (see 6.2) Apply the paint in a covered or enclosed space, shielded from wind, blowing dust and inclement weather, using the application parameters recommended by the coating material manufacturer and approved by the coater. The ambient temperature and relative humidity and the temperature of the steel surface application and subsequent drying/ curing shall be in accordance with the recommendations of the manufacturer of the coating material. The temperature of the steel shall be at least 30C above the dew point. In the case of accelerated curing, the temperature shall be as agreed between the coating material manufacturer and the coater. Spray the paint continuously and uniformly on to the whole surface to be coated. The coating shall be uniform, and particular attention shall be given to achieving the
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specified dry film thickness. Unless otherwise specified or agreed, maintain a cutback length of (20 + 5) mm. 6.5. Health and safety and protection of the environment It is the duty of clients, specifiers, contractors, coating material manufacturers, inspectors and all other personnel involved in the undertaking to carry out the work for which they are responsible in such a manner that they do not endanger the health and safety of themselves or others. In pursuance of this duty, each person shall ensure that all the statutory requirement of the country in which their work, or any part of the work, is carried out are complied with. 7. 7.1. PRODUCTION CONTROL Assessment of the coating on the pipes

7.1.1. Appearance Inspect the coating visually for uniformity of colour, smoothness and freedom from runs, holidays and other defects that could be detrimental to its quality. 7.1.2. Dry film thickness Unless otherwise specified or agreed, the minimum dry film thickness of the coating shall be 60 m above the peaks in the profile of the substrate and shall be determined in accordance with Annexure B. 7.2. 7.2.1. Assessment of the coating on steel panels Preparation of test panels Perform the tests specified in 7.2.2 to 7.2.5 on coating applied by spraying on to steel test panels, to give dry film thickness specified in 5.3.3. Prepare the test panels as specified in 6.2 and apply the paint in accordance with the instructions of the coating material manufacturer. Use conditioning cycle B or C (see 5.3.2). Perform each test at least in duplicate. Table 5 shows the required frequency of the tests specified in 7.2.2 to 7.2.5 7.2.2. Adhesion When determined in accordance with ISO 2409, the cross-cut classification of the
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coating shall be equal to or lower than 1. 7.2.3. Buchholz hardness When determined in accordance with ISO 2815, the Buchholz hardness of the coating shall be at least 94. 7.2.4. Bend test When determined in accordance with ISO 6860, the maximum extent of cracking along the panel from the small end of the mandrel shall be less than or equal to 13 mm, and there shall be no loss adhesion. 7.2.5. Curing test When tested in accordance with annex F, the coating shall not show any softening, wrinkling or blistering. 7.2.6. Porosity test The porosity of both the wet and the dry film shall be checked on glass panels by the method given in Annex E. Porosity is considered to be any coating defect (pinhole) through which light can pass directly. More than 5 pinholes shall constitute a failure. If the porosity test on a glass panel is deemed a failure, the wet-sponge test given in Annex G shall be carried out on the surfaces painted with the coating material which failed the glass panel test, testing at least ten areas, excluding welds. The coating on these surfaces shall not have more than 1 pinhole per 100 cm2 Table 5 Required frequency of, and acceptance criteria for, the production control tests specified in 7.2.2.to 7.2.5 Test Adhesion Bend test Buchholz hardness Curing test Method ISO 2409 ISO 6860 ISO 2815 Annex F Frequency Twice shift Twice shift Twice shift Twice per shift Acceptance criteria

per Classification 1 per No loss of Adhesion per Hardness 94 No softening, wrinkling or blistering

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8.

REPAIRS Defective coating, or areas with insufficient dry film thickness, shall be repaired in accordance with the coating material manufacturers recommendations. HANDLING, TRANSPORTATION AND STORAGE Handling Coated pipes shall be handled in such a way that no damaged is caused to the coating.

9. 9.1.

9.2 . Transportation to the storage area During transportation to the storage area at the coaters workshop, the coater shall take all relevant precautions to avoid damaged to the coating. 9.3. Storage Coated pipes shall be stored in such a way that the quality of the coating will not be affected. 9.4. Loading coated pipes for transportation When loading pipes at the workshop or in the field, all relevant precautions shall be taken to avoid the possibility of damage to the pipes or to the coating during transportation. The coater is responsible for ensuring that all pipes delivered to the purchaser are correctly coated and the coating is properly cured.

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ANNEX A : A.1 General

(NORMATIVE) DETERMINATION OF ASH (REFER TO SUB CLAUSE 5.2.5)

This annex describes a method for determining the ash residue from a coating. A.2 Apparatus

Ordinary laboratory apparatus, together with following: A.2.1 Porcelain crucible A.2.2 A2.3 A2.4 A.3. Muffle furnace Desiccator, containing an active desiccant Analytical balance, capable of weighing to 1 mg Procedure Weigh, to the nearest 1 mg, between 3g and 5 g of the product into a porcelain crucible (A.2.1). Place the crucible in a hood and heat with a low flame until the contents of the crucible are a dry, charred mass. Transfer to the muffle furnace (A.2.2) and ignite the residue at red heat (not exceeding 6000C) until the ash is free of carbon. Cool in the desiccator (A.2.3) and weigh. Repeat the igniting, cooling and weighing until the difference between successive weighing does not exceed 1 mg. A.4. Expression of results Calculate the ash WA, as a percentage by mass, using the following equation: WA (m1/m0) X 100 Where m1 is the mass, in grams, of the residue after ignition. m0 is the mass, in grams, of the test portion.
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(A.1)

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B.1.

General

ANNEX B : (NORMATIVE) DRY FILM THICKNESS (REFER TO SUB CLAUSE 5.3.3 AND 7.1.2)

This annex describes the measurement of the dry film thickness of a coating on a blastcleaned steel surface using an instrument based on the permanent-magnet principle or the inductive-magnet principle. If a coating has been applied to a blast-cleaned steel substrate, the measurement of the dry film thickness is more complicated than for smooth, flat surfaces. The effect of a surface roughness on the result increase with profile depth also related to the design of the measurement probe and the thickness of the coating. B.2. Apparatus Unless otherwise specified or agreed, the minimum dry film thickness of the coating shall be determined in accordance with ISO 2808:1997, Method No.10, using a singlepole instrument of the permanent-magnet or inductive-magnet type. B.3. Procedure Before use, ascertain that the instrument is in good working order (see manufacturers) Calibrate the instrument on a smooth, flat, level steel plate, using ISO 2808:1997, Method No.10. It will then be necessary to determine a correction factor by taking a series of readings on the unpainted blast-cleaned surface and calculating the average. All readings subsequently taken on the painted surface are then reduced by the correction factor to give the true value of the thickness above the peaks. Check the calibration at frequent intervals. For each pipe or fitting tested, at least 8 values shall be recorded. Each value shall be constituted by the arithmetic mean of 5 different measurement taken very close to the point at which the thickness is to be measured. When during a series of measurement an individual dry film thickness value does not meet the specified criterion, a repeat measurement not more than 10mm from the point of first measurement shall be carried out. The first value shall then rejected and replaced by the result of the repeat measurement. The maximum number of repeat measurements permitted is 2. If any measurement are less than 80% of the nominal dry film thickness (NDFT). Then the specimen fails this test. B.4. Results
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Calculate the arithmetic mean of the measurement values. Unless otherwise specified or agreed, the minimum dry film thickness of the coating shall be 60m above the peaks. In cases of dispute the result at one point, recalibrate the instrument and carry out five measurements, again very close to the point. Recalculate the arithmetic mean of the 5 measurements.

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C.1.

ANNEX C : (NORMATIVE) RESISTANCE TO GAS PRESSURE VARIATION (REFER TO SUB CLAUSE 5.3.9) General The test consists of verifying, by evaluation of visual appearance and determination of the adhesion, the behavior of the applied coating after it has been subjected to pressure variation in a gaseous environment (N2).

C.2.

Apparatus and materials

C.2.1 Sealed chamber, capable of resisting the test pressures during the whole of the test C.2.2 Nitrogen, as pressurizing gas. C.2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute C.3 Test specimens Substrates can be of two types: - approx. 100mm x 50mm x 1mm steel panels; - lengths of steel pipe approx. 100mm long with a minimum diameter of 80 mm or, if the diameter is too large for the pipe to fit into the chamber, specimens obtained from the pipe or fitting. The surface of the test panels or lengths of the pipe shall be prepared and coated at the same time and in the same way as the corresponding production surfaces. C.4 Procedure

C.4.1 General Unless otherwise specified by the coating material manufacturer, wait a month after the coating has been applied to the test panels or lengths of pipe before carrying out any test. C4.2 Cyclic Pressure Test This test is carried out as a qualification test on the inside coating. Put the specimen in the chamber and subject it to the set of 10 test cycles shown schematically in figure C.1, as follows:
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- Progressively increase the pressure in the chamber to 100 bar. - Keep the specimen under pressure for a fixed period of time to allow the pressurizing gas to penetrate into the coating: 20 h for the 1st to 4th cycles and the 6th to 9th cycles, 68 h for the 5th and 10th cycles; - Release the pressure rapidly over a few minutes (not more than 5 minutes); - Leave the coating at atmosphere pressure for 4 h to permit the development of any blisters on the coating, so that a cycle lasts either 24h or 72h (this latter period corresponds to the weekend, i.e. from Friday to Monday). Immediately at the end of the 10th test cycle, open the chamber and examine the appearance of the coating, noting all modifications (corrosion, spots or blisters).In addition, carry out an adhesion test in accordance with ISO 2409. Repeat the appearance examination after 24 h and after 48 h, again noting all modifications. Figure C.1 Complete set of pressure cycles.

C.4.3 Decompression blistering test The test is carried out only when the coated pipes are utilized at operating pressures higher than 100 bar. The test pressure shall be at least the pressure specified for that pipeline. Put the specimen in the chamber and then subject it to the specified pressure for 24 h so that the pressurizing gas can penetrate into the coating. Release the pressure rapidly over a few minutes (not more than 5 minutes) Immediately at the end of the test cycle, open the chamber and examine the
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appearance of the coating, noting all modifications (corrosion, spots or blisters).In addition, carry out an adhesion test in accordance with ISO 2409. Repeat the appearance examination after 24 h and after 48 h, again noting all modifications. C.5 Results Record any degradation observed immediately on removing the specimen from the chamber and indicates any further changes after 24 h and 48 h. Record the adhesion of the coating measured in the adhesion test.

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ANNEX D : (NORMATIVE) HYDRAULIC- PRESSURE BLISTERING (REFER TO SUB CLAUSE 5.3.12) D.1 General The test consists of verifying, by evaluation of the visual appearance and determination of the adhesion, the behavior of the applied coating when subjected to pressure variation in a liquid environment (water/CaCO3). D.2 Apparatus and materials

D.2.1 Sealed chamber, capable of resisting the test pressure during the whole of the test. D.2.2 Water saturated with CaCO3, as pressurizing liquid. D.2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute. D.3 Test specimens Substrates can be of two types: - approx. 100 mm x 1 mm steel panels; - lengths of steel pipe approx. 100 mm long with a minimum diameter of 80 mm or, if the diameter is too large for the pipe to fit into the chamber, specimens obtained from the pipe or fitting. The surfaces of the test panels or length of the pipe shall be prepared and coated at the same time and in the same way as the corresponding production surfaces. D.4 Procedure Unless otherwise specified by the coating material manufacturer, wait a month after the coating has been applied to the test panels or lengths of pipe before carrying out any test. This test is carried out at least 100 bar if the maximum operating pressure is 100 bar or less. If the operating pressure is higher than 100 bar, the test pressure shall be at least the pressure specified for that pipeline. Put the specimen in the chamber and then subject it to the specified pressure specified for 24 h so that the pressurizing liquid can be penetrate into the coating. Release the pressure rapidly over a few minutes (not more than 5 minutes).
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Immediately at the end of the test cycle, open the chamber and examine the appearance of the coating, noting all modifications (corrosion, spots or blisters).In addition, carry out an adhesion test in accordance with ISO 2409. Repeat the appearance examination after 24 h and after 48 h, again noting all modifications.

D.5

Results Record any degradation observed immediately on removing the specimen from the chamber and indicates any further changes after 24 h and 48 h. Record the adhesion of the coating measured in the adhesion test.

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ANNEX E : (NORMATIVE) POROSITY OF A FILM OF THE COATING MATERIAL ON A GLASS PANEL (REFER TO SUB CLAUSE 7.2.6) Use a glass panel measuring approx. 75 mm x 25 mm x 2 mm and frosted on one side. Clean the panel by immersion in a suitable solvent and then in acetone. Allow the panel to dry in air for a few seconds. Place a panel inside the pipe to be coated with non-frosted side facing the wall of the pipe; keep it in position at each end by means of adhesive tape (max. overlap on glass 10 mm). Just before coating, check that the panel is free from dust or pollution. Apply the coating material to glass panel during the pipe-coating process. Then examine the panel as follows: (a) Wet film- Five minutes after application of the coating material, place the glass panel over an opaque (dark) shield measuring approx. 300 mm x 300 mm with a 50 mm x 20 mm slot in the middle. Hold the panel, together with the shield, 130 mm from an illuminated 100 W bulb, with the shield facing the bulb. Check for pinholes. More than 5 pinholes shall constitute a failure. (b) Cured film-If the coating is acceptable in the wet state, allow it to cure for an additional 30 min in air at 18 oC to 25 oC and a relative humidity of 80 %, and then place in a circulating-air oven at (75 + 2 ) oC for a minimum of 30 min. repeat the examination described above. More than 5 pinholes shall constitute a failure. Another curing schedule may be agreed between the coater and the coating material manufacturer. NOTE : if justified by the prevailing application and drying conditions or the type of paint used, the test conditions may be modified by agreement between the interested parties.

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ANNEX F: (NORMATIVE) CURING TEST (REFER TO SUB CLAUSE 7.2.5) Apply the coating material to steel pannels and condition the coated pannels as specified in 7.2.1. Test for resistance to the thinner which is recommended for thinning the coating material, in accordance with ISO 2812-1 , for 4h. Examine the panels after a recovery period of 30 min at 18 o C to 25 o C and 80 % relative humidity following removal of the panels from the test liquid. The coating shall not show any softening, wrinkling or blistering.

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ANNEX G: (NORMATIVE) WET SPONGE TEST (REFER TO SUB CLAUSE 7.2.6) G1 G.2 General Apparatus and materials

G.2.1 Adjustable low-voltage wet-sponge tester, equipped with an alarm, an electrode in the form of a sponge and conductors for connecting the coated pipe or fitting under test to earth. G.2.2 Tap water G.3 Procedure Set the test voltage to 9 V. Connect up the instrument, connecting the earth lead, by means of a crocodile clip, to an uncoated section of the metal of the surface under test. Moisten the sponge with tap water. Note that too much water will affect the performance. Switch on the electrode and move it continuously in connect with the surface of the coating to be inspected; the rate of travel of the electrode is not limited, but it shall not be higher than the speed at which it can be demonstrated that a porosity defect can be detected. The presence of a porosity defect is indicated by the emission of a high-pitched note from the alarm. G.4 Results Record the number of porosity defects per 100 cm2.

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STANDARD SPECIFICATION FOR PIPELINE BALL VALVES

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STANDARD SPECIFICATION FOR PIPELINE BALL VALVES (ONSHORE)

SPECIFICATION S 04 02 007

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CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 FIG. 4.9 SCOPE REFERENCE DOCUMENTS MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING MARKING AND SHIPMENT SPARES AND ACCESSORIES DOCUMENTATION VENT, DRAIN AND SEALANT DETAILS

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1.0

SCOPE This specification covers the minimum requirements for design, manufacture and supply of carbon steel ball valves of size DN 50 mm (2) and above and ANSI class 150# thru 900# for use in onshore pipeline systems handling non sour hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG). This specification does not cover ball valves for sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-0l-75.

2.0 2.1

REFERENCE DOCUMENTS All valves shall be manufactured and supplied in accordance with the latest edition of American Petroleum Institute (API) Specification 6D, Twenty Second edition, January 2002/ ISO 14313:1999, Petroleum and Natural Gas Industries Pipeline Transportation Systems- Pipeline Valves, with additions and modifications as indicated in the following sections of this specification. Reference has also been made in this specification to the latest edition of the following Codes, Standards and Specifications. ASME B31.3 ASME B31.4 ASME B31.8 ASME B16.5 ASME B16.10 ASME B16.47 ASME B16.25 ASME B16.34 API 1104 ASME Sec VIII ASME Sec IX Process Piping

2.2

- Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids Gas Transmission and Distribution Piping Systems Pipe Flanges and Flanged Fittings Face to Face and End to End Dimensions of Valves Large Diameter Steel Flanges Butt-welding Ends Valves - Flanged, Threaded and Welding Ends. Welding Pipelines and Related Facilities Boiler and Pressure Vessel Code- Rules for Construction of Pressure Vessels. Boiler and Pressure Vessel Code-Welding and Brazing Qualifications
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ASTM A-370 ASTM B-733 MSS-SP-6 MSS-SP-44 SSPC-VIS-1 2.3

- Standard Test Methods and Definitions for Mechanical Testing of Steel Products - Auto catalytic Nickel Phosphorous Coating on Metals - Standard Finishes for Contact Faces of Pipe Flanges and Connecting- end Flanges of Valves and Fittings. - Steel Pipeline Flanges. - Steel Structures Painting Council Visual Standard.

In case of conflict between the requirements of this specification, API 6D and the Codes, Standards and Specifications referred in clause 2.2 above, the requirements of this specification shall govern. MATERIALS Material for major components of the valves shall be as indicated in Valve Data Sheet. Other components shall be as per Manufacturers standard (suitable for the service conditions indicated in the data Sheet) and shall be subject to approval by Purchaser. In addition, the material shall also meet the requirements specified hereinafter. All process wetted parts, metallic and non metallic, and lubricants shall be suitable for the service specified by the Purchaser. Manufacturer shall confirm that all wetted parts are suitable for treated water/ sea water environment, which may be used during field testing. Non metallic parts of the valves (including O-rings, soft seals etc.) intended for hydrocarbon gas service shall be resistant to explosive decompression.

3.0 3.1

3.2 3.3

Carbon steel used for the manufacture of valves shall be fully killed. The carbon equivalent (CE) of valve end connections which are subject to further field welding by Purchaser shall not exceed 0.45 on check analysis for each heat of steel used, as calculated by the following formula:

3.4

For valves specified to be used for Gas service or High Vapour Pressure (HVP) liquid service/ LPG service, Charpy V-notch test on each heat of base material shall be conducted as per API 6D, Clause -7.5, for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall be
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conducted at 0C. Test procedure shall confirm to ASTM A370. The Charpy V-notch test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22 J. For valves specified to be used for other hydrocarbon services, Charpy V-notch requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with. 3.5 For all such valves where Carbon Steel is used as ball material, the ball shall have 75 micrometers (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B 733 with following classification: SC2, Type II, Class 2.

The hardness of plating shall be minimum 50 RC. 3.6 When the valves are specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out on each heat of base material for all pressure containing parts of the valve. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire thickness. For valves specified to be used for Low Vapour Pressure (LVP) liquid service, requirements as stated herein above are not applicable. 4.0 4.1 DESIGN AND CONSTRUCTION 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 ASME B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. However, the minimum wall thickness shall not be less than the minimum requirement of ASME B 16.34. The manufacturer shall have valid license to use API monogram on valves manufactured as per API 6D.

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4.2 4.3 4.4

Valve body design shall be either fully welded or bolted. Valve body joints with threads are not permitted. Ball shall be of single piece, solid type construction. Valves shall be Full bore (FB) or Reduced bore (RB) as indicated in the Valve Data Sheet. Full bore valves shall be suitable for the passage of all types of pipeline scraper and inspection pigs on regular basis without causing damage to either the valve component or the pig. The full bore valve shall provide an unobstructed profile for pigging operations in either direction. Full bore valves shall be designed to minimize accumulation of debris in the seat ring region to ensure that valve movement is not impeded. In case of reduced bore valves, the nominal valve size indicated in the Valve Data Sheet shall correspond to that of a full bore valve of smaller nominal diameter as indicated in Table-4.4 of this specification. For sizes of a particular rating not covered in API 6D, the bore size of reduced bore valve shall be as per Manufacturers standard. TABLE - 4.4
Nominal Valve Size, Nominal Valve size for Reduced Bore Nominal Valve Size, Nominal Valve Size for Reduced Bore

DN mm (NPS inches) DN mm (NPS inches) DN mm (NPS inches)


50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 500 (20) 550 (22) 50 (2) 50 (2) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10) 250 (10) 300 (12) 350 (14) 400 (16) 450 (18) 600 (24) 650 (26) 700 (28) 750 (30) 800 (32) 850 (34) 900 (36) 950 (38) 1000 (40) 1050 (42) 1200 (48) -

DN mm (NPS inches)
500 (20) 550 (22) 600 (24) 600 (24) 650 (26) 700 (28) 750 (30) 800 (32) 850 (34) 900 (36) 1050 (42) -

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4.5

Ball mounting shall be trunnion or pivot type only. Valve design shall minimize the possibility of debris ingress into the trunnion as far as practicable. Valve seats shall be with primary metal to metal contact. O-rings or other seals if used for drip tight sealing shall be encased in a suitable groove in such a manner that it can not be removed from seat ring and there is no extrusion during opening or closing operation 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. Seat design with PTFE inserts is not applicable. Valves shall have double block and bleed feature to facilitate complete flush, drain and venting of the valve body cavity. For valves to be used in liquid service, the body cavity over-pressure shall be prevented by self-relieving seat rings/assemblies. A pressure relief hole in the ball is not permitted. Self-relieving seat rings shall relieve at a body cavity differential pressure not exceeding 50% of the valve class rating pressure. When specified in the Valve Data Sheet, valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both open and closed positions. Full Bore valves of nominal valve size 200 mm (8) & above and Reduced Bore valves of nominal valve size 250 mm (10) & above, shall have provision for secondary sealant injection under full line pressure for seat and stem seals. All sealant injection connections shall be provided with an internal non-return valve. Valve design shall have a provision to replace the sealant injection fitting under full line pressure. Location and arrangement of sealant point shall be as per Fig. 4.9.

4.6

4.7

4.8

4.9

4.10 Valves shall be provided with vent and drain connections. Location and arrangement of vents and drains shall be as per Fig. 4.9. Body vent and drain shall be provided with valves (Ball or Plug type). Number and size shall be as per Fig. 4.9. 4.11 Valve design shall ensure repair of stem seals/packing under full line pressure. 4.12 Valve design shall be as to avoid bimetallic corrosion between carbon steel and high alloy steel components, suitable insulation shall be provided as required. 4.13 a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast/ forged body valves shall be integrally cast/ forged with the body of the valve. Face to face/end to end dimensions shall conform to API 6D. Face to Face and end to end dimensions for valve sizes not specified in API 6D shall be in accordance with ASME B 16.10. Face to face and end to end dimension not shown in API 6D or ASME B16.10 shall be as per Manufacturers Standard and shall be subject to approval by Company.
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b)

Flanged end, if specified, shall have dimensions as per ASME B16.5 for valve sizes upto DN 600 mm (24) excluding DN 550 mm (22) and as per MSS-SP44/ ASME B16.47 Series A for valve sizes DN 550 mm (22) and for DN 650 mm (26 inches) and above. Flange face shall be either raised face or ring joint type (RTJ) as indicated in Valve Data Sheet. Flange face finish shall be serrated or smooth as indicated in Valve Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe to which the valve has to be welded shall be as indicated in the Valve Data Sheet. Valves shall be without transition pups. In case difference exists between thickness of welding ends of valve and connecting pipe, the welding ends of valve shall have bevel preparation as per ASME B31.4 or ASME B31.8 as applicable.

c)

4.14

Design of weld end valves shall be such that during field welding operation, soft seals or plastic components of the valve (where ever used) are not liable to be damaged. The manufacturer shall furnish necessary field welding instructions and post weld test procedure to demonstrate integrity and leak tightness of valves after field welding operations.

4.15 Valve shall be provided with ball position indicator and stops of rugged construction at the fully open and fully closed positions. 4.16 Full Bore valves of nominal valve size, DN 200 mm (8) and Reduced Bore valves of nominal valve size, DN 250 mm (10), shall be equipped with support foot and lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot shall be kept minimum. The location and size of support foot/ lifting lugs shall ensure unrestrictive operation of vent/ drain valves. 4.17 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. 4.18 Valves shall be suitable for either buried or above ground installation as indicated in Valve Data Sheet. 4.19 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions. a) 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 centerline of the valve
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opening and the top of mounting flange for valve operating device (gear operator/ power actuator as applicable). b) Vent and drain connections and sealant injection lines shall be terminated adjacent to the valve operator by means of suitable piping anchored to the valve body. The pipe used shall be API 5L Gr. B / ASTM A 106 Gr. B, with Sch. 160. Fittings shall be ASTM A105/ASTM A234 Gr. WPB, Socket welded ANSI class 6000. Stem extension and stem housing design shall be such that the complete assembly will form a rigid unit giving positive drive under all conditions with no possibility of free movement between valve body, stem extension or its operator. Outer casing of stem extension shall have 3/8 or NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion.

c)

d)

4.20 OPERATING DEVICES a) Valves shall have a power actuator or manual operator as indicated in the Valve Data Sheet. In case of manual operator, valve sizes, DN 100 mm (4) shall be wrench operated and valve sizes, DN 150 mm (6) shall be gear operated. Valve design shall be such that damage due to malfunctioning of the operator or its controls will only occur in the operator gear train or power cylinder and that damaged parts can be replaced without the valve cover being removed. The power actuator shall be in accordance with the Purchaser Specification issued for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open /full open to full close under maximum differential pressure corresponding to the valve rating. For actuated valves, the actuators 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. For the manual operator of all valves, the diameter of the hand wheel or the length of operating wrench shall be such that under the maximum differential pressure, the total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position.

b)

c)

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d)

Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the valve. Hand wheels shall not have protruding spokes. Gear operators, when provided, shall have a self-locking provision and shall be fully encased in water proof/ splash proof enclosure and shall be filled with suitable grease.

e)

4.21 All welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Section IX. The procedure qualification shall also include impact test and hardness test when required as per Clause 3.4 and 3.6 of this specification and shall meet the requirements as specified therein. 4.22 Repair by welding is not permitted for fabricated and forged body valves. However repair by welding as per ASME B16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall also include impact test and hardness test when required as per Clause 3.4 and 3.6 of this specification and shall meet the requirements as specified therein. 4.23 The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall be as per connected pipe specification as indicated in the Valve Data Sheet.

4.24 Valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME section VIII, Division 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. 5.0 5.1 INSPECTION AND TESTS The Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests shall be, but not limited to, the following:

5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves shall be free from any strikes, gouges, and other detrimental defects. The surface shall thoroughly cleaned and free from dirt, rust and scales. 5.1.2 Dimensional check on all valves shall be carried out as per the Purchaser approved drawings.

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5.1.3 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.4 a) Non-destructive examination of individual valve material and component consisting of but not limited to castings, forgings, plates and assembly welds shall be carried out by the Manufacturer. 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 as under:

b)

Pressure Class Rating ANSI 150 # Class ANSI 300 # Class ANSI 600 # Class and above

Valve Size All sizes DN 400 mm (16) DN450 mm (18) All sizes

Extent of Radiography Nil Nil 100% 100%

All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B16.34. c) All valves, with body fabricated from plates or made by forgings, shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure-E of ASME B16.34. All forgings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B 16.34. Bodies and bonnets made by welded assembly of segments of castings, forgings, plates or combinations thereof shall be examined, as applicable, by methods of 5.1.4 (b) for cast components or 5.1.4 (c) for forged components and plates.

d)

5.1.5 Full inspection by radiography shall be carried out on all welds of pressure containing parts. Acceptance criteria shall be as per ASME B 31.4 or ASME B3 1.8 as applicable and API 1104. 5.1.6 Welds, which in Purchasers opinion cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively.

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5.1.7

a) All finished wrought weld ends subject to welding in field shall be 100% ultrasonically tested for lamination type defects for a distance of 50 mm from the end. Laminations shall not be acceptable. b) c) Weld ends of all cast valves subject to welding in field shall be 100% radiographically examined and acceptance criteria shall be as per ASME B16.34. After final machining, all bevel surfaces shall be inspected by dye penetrant or wet magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the defects between 6.35 mm and 1.59 mm that are separated by a distance lessthan50timestheir greatest length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted.

5.1.8 All valves shall be tested in compliance with the requirements of API 6D. During pressure, testing, valves shall not have sealant lines and other cavities filled with sealant, grease or other foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. The body cavity self-relieving feature meeting the requirements of clause 4.7 of this specification shall also be checked. 5.1.9 A supplementary air seat test as per API 6D (Appendix C, Para C.3.3) shall be carried out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be held for at least 15 minutes. 5.1.10 Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6 of API 6D under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force required to operate the valve does not exceed the requirements stated in section 4.20 (c) of this specification. 5.1.11 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve Manufacturers 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 with in the limits stated in Valve Data Sheet. Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and the actuator model/type. In case, the tests do not meet the requirements, retesting/ rejection of the lot shall be decided by the Purchasers Inspector.
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5.1.12 Subsequent to successful testing as specified in clause 5.1.8, 5.1.9, 5.1.10 and 5.1.11 above, one (1) valve out of the total ordered quantity shall be randomly selected by the Company Representative for cyclic testing as mentioned below: a) b) The valve shall be subjected to at least 100 Open-Close-Open cycles with maximum differential pressure corresponding to the valve rating. Subsequent to the above, the valve shall be subjected to hydrostatic test and supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.

In case this valve fails to pass these tests, the valve shall be rejected and two more valves shall be selected randomly and subjected to testing as indicated above. If both valves pass these tests, all valves manufactured for the order (except the valve that failed) shall be deemed acceptable. If either of the two valves fails to pass these tests, all valves 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 same has been carried out by manufacturer in last two years. Valves of two sizes below and two sizes above the size of valve previously tested, and rating similar or one rating lower of valve tested previously, shall be qualified. 5.2 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in clause 5.1 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchasers Inspector. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturers account. In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchasers Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests. 6.0 TEST CERTIFICATES Manufacturer shall submit the following certificates: a) Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards.

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b) c) d)

Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test. Test reports of radiograph and ultrasonic inspection. Test report on operation of valves conforming to clause 5.1.10, 5.1.11 and 5.1.12 of this specification.

e) All other test reports and certificates as required by API 6D and this specification. The certificates shall be valid only when signed by Purchasers Inspector. Only those valves which have been certified by Purchasers Inspector shall be dispatched from Manufacturers works. 7.0 7.1 PAINTING, MARKING AND SHIPMENT Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with Steel Structures Painting Council Visual Standard SSPC-VIS-1. For the valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. 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 a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors. All sealant lines and other cavities of the valve shall be filled with sealant before shipment. Packaging and shipping instructions shall be as per API 6D. On packages, following shall be marked legibly with suitable marking ink: a) b) c)
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7.2 7.3

7.4 7.5 7.6

Order Number Manufacturers Name Valve size and rating


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d) e) 8.0 8.1 8.2 8.3 9.0 9.1

Tag Number Serial Number

SPARES AND ACCESSORIES Manufacturer shall furnish list of recommended spares and accessories for valves required during start-up and commissioning. Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of valves. Manufacturer shall quote for spares and accessories as per Material Requisition. DOCUMENTATION At the time of bidding, Manufacturer shall submit the following documents: a) General arrangement/ assembly drawings showing all features and relative positions and sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts together with overall dimension. Sectional drawing showing major parts with reference numbers and material specification. In particular a blow up drawing of ball-seat assembly shall be furnished complying the requirement of clause 4.6 of this specification. Reference list of similar ball valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service etc. Torque curves for the power actuated valves along with the break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves. Clause wise list of deviations from this specification, if any. Descriptive technical catalogues of the manufacturer. Installation, Operational and Maintenance Manual. Copy of valid API 6D Certificate. Details of support foot including dimensions and distance from valve centerline to bottom of support foot. List of recommended spares required during start-up and commissioning.
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b)

c)

d)

e) f) g) h) i) j)

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k) 9.2

List of recommended spares required for 2 years of normal operation and maintenance.

With in three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for Purchasers approval: a) b) Detailed sectional drawings showing all parts with reference numbers and material specifications. Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme. Complete dimensional details of support foot (where applicable) shall be indicated in these drawings. Welding, heat treatment and testing procedures. Details of corrosion resistant paint to be applied on the valves. Design calculation for pressure containing Parts. Procedure for cycle testing.

c) d) e) f)

Manufacture of valves shall commence only after approval of the above documents. Once the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. 9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of the approved drawings, documents and specifications as listed in clause 9.2 above. Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the following: a) b) 9.5 Test certificates as per clause 6.0 of this specification Manual for installation, erection, maintenance and operation instructions including a list of recommended spares for the valves.

9.4

All documents shall be in English language only.

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STANDARD SPECIFICATION FOR PIPELINE PLUG VALVES

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CONTENTS
Sl. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 DESCRIPTION SCOPE REFERENCE DOCUMENTS MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT SPARES AND ACCESSORIES DOCUMENTATION

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1.0

SCOPE This Specification covers the minimum requirements for design, manufacture and supply of carbon steel plug valves of size DN 50 mm (2 inch) and above and ANSI class 150# thru 900# for use in onshore pipeline systems handling non sour hydrocarbons in liquid phase or gaseous phase including Liquefied Petroleum Gas (LPG). This specification does not cover plug valves for sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-0l-75.

2.0 2.1

REFERENCE DOCUMENTS All valves shall be manufactured and supplied in accordance with the American Petroleum Institute (API) Specification 6D, Twenty second edition, January 2002 / ISO 14313:1999, Petroleum and Natural Gas Industries Pipeline Transportation Systems Pipeline Valves, with addition and modification as indicated in the following sections of this specification. Reference has also been made in this specification to the latest edition of the following Codes, Standards and Specifications: ASME B 31.3 ASME B 31.4 ASME B 31.8 ASME B 16.5 ASME B 16.25 ASME B 16.34 ASME B 16.47 API 1104 ASME Sec VIII/IX ASTM A 370 ASTM B 733 : : : : : : : : : : : Process Piping. Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids. Gas Transmission and Distribution Piping Systems. Pipe Flanges and Flanged Fittings. Butt-welding Ends Valves -- Flanged, Threaded and Welding Ends. Large Diameter Steel Flanges. Welding Pipelines and Related Facilities. Boiler and Pressure Vessel Code. Test Methods and Definitions for Mechanical Testing of Steel Products. Auto catalytic Nickel Phosphorous Coating on Metals.

2.2

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MSS-SP-6 MSS-SP-44 SSPC-VIS-1 2.3

: : :

Standard Finishes for Contact Faces of Pipe Flanges and Connecting-end Flanges of Valves and Fittings. Steel Pipe Line Flanges. Steel Structures Painting Council Visual Standard.

In case of conflict between the requirements of this specification, API 6D and the Codes, Standards and Specifications referred in clause 2.2 above, the requirements of this specification shall govern. MATERIALS Material for major components of the valves shall be as indicated in Valve Data Sheet. In addition, the material shall also meet the requirements specified herein. Other components shall be as per Manufacturers standard, which shall be subject to approval by Purchaser. Carbon steel used for the manufacture of valves shall be fully killed. The Carbon Equivalent (CE) of valve end connections which are subject to further field welding by Purchaser shall not exceed 0.45 in check analysis for each heat of steel used, as calculated by the following formula:

3.0 3.1

3.2 3.3

CE = C+ Mn + Cr+Mo+V+ Ni+Cu 6 5 15
3.4 For valves specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 3.7 for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0 C. The Charpy V-notch test specimen shall be taken in the direction of - principal grain flow and notched perpendicular to the original surface of plate or forging. The minimum average absorbed energy per set of three specimens shall be 27 J with an individual minimum per specimen of 22 J. For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall be complied with.

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3.5

For all such valves where Carbon Steel /S.G. Iron is used as plug material, the plug shall have 75 microns (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B733 with following classification: SC2, Type II, Class 2. The hardness of plating shall be minimum 50 RC.

3.6

When the valves are specified to be used for Gas service or High Vapour Pressure (HVP) liquid ervice, hardness test shall be carried out on each heat of base material for all pressure containing parts of the valve. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire thickness. For valves specified to be used for Low Vapour Pressure (LVP) liquid service, requirements as stated herein above are not applicable.

4.0 4.1

DESIGN AND CONSTRUCTION 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 ASME B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be considered in valve design. However, the minimum wall thickness shall not be less than the minimum requirement of ASME B 16.34. The manufacturer shall have valid license to use API monogram on valves manufactured as per API 6D.

4.2

Valve pattern area shall be as specified in the following table:

ANSI Rating 150

300 600 900

Size Range, DN mm (inch) 50-100 (2-4) 150-300 (6-12) 350 (14) & above 50-100 (2-4) 150-300 (6-12) 350 (14) & above 50-250 (2-10) 300 (12) & above 50-250 (2-10) 300 (12) & above

Pattern Short Regular Venturi Short Regular Venturi Regular Venturi Regular Venturi

4.3

Valves shall have an inherent feature using line pressure to ensure that the line pressure cannot cause taper locking of the plug / plug movement into the taper, i.e. valves shall be of pressure - balanced design.

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4.4 4.5 4.6

Cover shall be bolted to the body and screwed connections are not acceptable. Soft seats to achieve a seal between plug and body are not permitted. All valves shall have the provision for secondary sealant injection under full line pressure for seat and stem seals. All sealant injection connections shall be provided with an internal non-return valve. Valve design shall have a provision (e.g. Ball Type Check Valve/Needle Valve) to replace the sealant injector fitting under full line pressure. Location and arrangement of sealant injection points shall be as per Figure-4.6. When specified in the Vale Data Sheet, valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in both open and closed position. Valve design shall ensure repair of gland packing under full line pressure. a) Valve ends shall be either flanged or butt-welded or one end flanged and one end butt welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast body valves shall be integrally cast with the body of the valve. Face to face/end to end dimensions shall conform to API 6D. b) Flanged end shall have dimensions as per ANSI B16.5 for valve sizes upto DN 600 mm (24) (excluding DN 550 mm (22)) and as per MSS-SP-44 /ASME B16.47 Series A for valve sizes DN 550 mm (22) and for DN 650 mm (26) and above. Flange face shall be either raised face or ring joint type as indicated in Purchase Requisition. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. Butt weld end preparation shall be as per ASME B 16.25. The thickness of the pipe to which the valve has to be welded shall be as indicated in the Valve Data Sheet. Valves shall be without transition pups. In case difference exists between thickness of welding ends of valves and connecting pipe, the Data Sheet shall be considered in valve design. However the minimum wall thickness shall not be less than the minimum requirement of ASME B 16.34. The welding ends of valve shall have bevel preparation as per ASME B31.4/ B31.8 as applicable.

4.7

4.8 4.9

c)

4.10 Valves shall be provided with plug position indicator and stops of rugged construction at the fully open and fully closed positions. 4.11 When indicated in Material Requisition, valves shall have locking devices to lock the valve either in full open (LO) or full close (LC) position. Locking devices shall be permanently attached to the valve operator and shall not interfere with operation of the valve.

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4.12 Valves shall be suitable for either buried or aboveground installation as indicated in Valve Data Sheet. 4.13 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the following provisions: a) Valves provided with stem extension shall have waterproof outer casing. Length of stem extension shall be as indicated in Valve Data Sheet. The length indicated corresponds to the distance between centerline of the valve opening and the top of mounting flange for valve operating device (gear operator/power actuator as applicable) Seat sealant injection lines shall be extended and terminated adjacent to the valve operator by means of suitable piping anchored to the valve body/ stem housing. The pipe used shall be API 5L Gr. B/ ASTM A106 Gr. B, with Sch. 160. Fittings shall be ASTM A105/ ASTM A234 Gr. WPB, Socket welded ANSI Class 6000. Stem extension and stem housing design shall be such that the complete assembly will form a rigid unit giving positive drive under all conditions with no possibility of free movement between valve body, stem extension or its operator. Outer casing of stem extension shall have or NPT plugs at the top and bottom, for draining and filling with oil to prevent internal corrosion.

b)

c)

d)

4.14 Operating Devices a) Valves shall have a power actuator or manual operator as indicated in the Valve Data Sheet. In case of manual operator, valve sizes DN 100 mm (4) shall be wrench operated and valve sizes DN 150 mm (6) shall be gear operated. 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 power actuator shall be in accordance with the Purchaser specification issued for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open/ full open to full close under maximum differential pressure corresponding to the valve rating. For actuator valves, the actuator rated torque output shall be at least 1.25 times the break torque required to operate the valve under maximum differential pressure corresponding to the valve class rating. For the manual operator of all valves, the diameter of the hand wheel or the length of operating Wrench shall be such that under the maximum
STANDARD SPECIFICATION FOR PIPELINE PLUG VALVES SPECIFICATION S 04 02 008 REV-0 Page 7 of 14

b)

c)

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differential pressure, total force required to operate the valve does not exceed 350N. Manufacturer shall also indicate the number of turns of hand wheel (in case of gear operator) required to operate the valve from full open to full close position. d) e) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing the valve. Gear operators, when provided, shall have a self-locking provision and shall be fully encased in water proof/splash proof enclosure and shall be filled with suitable grease.

4.15 Repair by welding is not permitted for fabricated and forged body valves. However repair by welding as per ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of casting is done. Repair welding procedure qualification shall also include impact test and hardness test when required as per Clause 3.4 and 3.6 of this specification and shall meet the requirements as specified therein. 4.16 The tolerance on internal diameter and out of roundness at the ends for welded ends valves shall be as per connected pipe specification as indicated in the Valve Data Sheet. 4.17 Valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure corresponding to applicable class rating. The combined stress shall not exceed the maximum allowable stresses specified in ASME section VIII, Division 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 the valve stem. 5.0 5.1 INSPECTION AND TESTS The Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests shall be, but not limited to, the following:

5.1.1 Visual and dimensional check on all valves shall be carried out as per the Purchaser approved drawings. 5.1.2 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 5.1.3 a) Non destructive examination of individual valve material and components consisting of but not limited to castings/ forgings shall be carried out by the Manufacturer.
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b)

Body castings of valves shall be radio-graphically examined as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B16.34. The extent of radiography shall be as follows: ANSI Class 150# ANSI Class 300# ANSI Class 600# and above All sizes DN 400mm (16) DN 450mm (18) All sizes Nil Nil 100% 100%

All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method and acceptance shall comply with ASME B 16.34. c) All valves made by forgings shall be ultrasonically examined in accordance with the procedure and acceptance standard of Annexure E of ASME B16.34.

5.1.4 Areas, which in Purchasers opinion cannot be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively. 5.1.5 a) Weld ends of all cast valves subject to welding in field shall be 100 % radiographically examined and acceptance criteria shall be as per ASME B16.34. b) After final machining, all bevel surfaces shall be inspected by dye penetrant or wet magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the defects between 6.35 mm and 1.59mm that are separated by a distance less than 50 times their greatest length. Rejectable defects must be removed. Weld repair of bevel surface is not permitted. c) All finished wrought weld ends subjects to welding in field shall be 100 percent ultrasonically tested for lamination type defects for a distance of 50 mm from the end. Laminations shall not be acceptable.

5.1.6 All valves shall be tested in compliance with the requirements of API 6D. The sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. 5.1.7 A supplementary air seat test as per API 6D Appendix C3 shall be carried out for all valves.. No leakage is allowed. Test pressure shall be held for at least 15 minutes. 5.1.8 Valves shall be subjected to Operational Torque Test as per API 6D Appendix C4 under hydraulic pressure equal to maximum differential pressure corresponding to the valve rating. For manually operated valves, it shall be established that the force
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required to operate the valve does not exceed the requirements stated in section 4.14(c) of this specification. 5.1.9 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve Manufacturers works. At least five Open-Close-Open cycles without internal pressure and five Open-Close-Open cycles with maximum differential pressure corresponding to 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 Valve data sheet. Hand operator provided on the actuator shall also be checked after the cyclic testing, for satisfactory manual over-ride performance. These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the same size, rating and actuator model/type. In case the tests do not meet the requirements, retesting/rejection of the lot shall be decided by purchasers Inspector. 5.2 Purchaser reserves the right to perform stage wise inspection and witness tests as indicated in clause 5.1 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchasers inspector. Purchaser reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to Manufacturers account. In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. Inspection and tests performed/witnessed by the Purchasers inspector shall in no way relieve the manufacturers obligation to perform the required inspection and tests. 6.0 TEST CERTIFICATES Manufacturer shall submit the following certificates: a) Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for the valve construction as per the relevant standards. Test certificates of hydrostatic and pneumatic tests complete with records of timing and pressure of each test. Test reports of radiography and ultrasonic inspection.

b) c)

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d) e)

Test report on operation of valves conforming to clause 5.1.8 and 5.1.9 of this specification. All other test reports and certificates as required by API 6D and this specification.

The certificates shall be valid only when signed by Purchasers Inspector. Only those valves which have been certified by Purchasers Inspector shall be dispatched from Manufacturers works. 7.0 7.1 PAINTING, MARKING AND SHIPMENT Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with Steel Structures Painting Council Visual Standard SSPC-VIS-l. For the valves to be installed underground, when indicated in Valve Data Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. 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 a coat of grease or other suitable material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. Bevel ends shall be protected with metallic or high impact plastic bevel protectors. All sealant lines and other cavities of the valve shall be filled with sealant before shipment. Packaging and shipping instructions shall be as per API 6D. On packages, the following shall be marked legibly with suitable marking ink: a) b) c) d) e) 8.0 Order Number Manufacturers Name Valve size and rating Tag Number. Serial Number

7.2 7.3

7.4 7.5 7.6

SPARES AND ACCESSORIES


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8.1 8.2 8.3 9.0 9.1

Manufacturer shall furnish list of recommended spares and accessories for valves required during start-up and commissioning. Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of valves. Manufacturer shall quote for spares and accessories as per Material Requisition. DOCUMENTATION At the time of bidding, Manufacturer shall submit the following documents: a) General arrangement drawings showing all features and relative positions and sizes of vents, drains, gear operator/actuator, painting, coating and other external parts together with overall dimensions. Sectional drawing showing major parts with reference numbers and material specification. Torque curves for the power actuated valves along with break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for power actuated valves. Reference list of similar plug valves manufactured and supplied in last five years indicating all relevant details including project, year, client, location, size, rating, service etc. Descriptive technical catalogues of the manufacture. Clause wise list of deviation from the specification, if any. Installation, Operational and Maintenance Manual. Copy of valid API 6D Certificate.

b) c)

d)

e) f) g) h) 9.2

Within three weeks of placement of order, the Manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for Purchasers approval: a) b) Detailed sectional drawings showing all parts with reference numbers and materials specification. Assembly drawings with overall dimensions and features. Drawing shall also indicate the number of turns of hand wheel (in case of gear operators) required for operating the valve from full open to full close position and the painting scheme.
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c) d) e)

Fabrication details of all valves. Welding, Heat treatment and Testing procedures. Details of corrosion resistant paint to be applied on the valves.

Manufacture of valves shall commence only after approval of the above documents. Once, the approval has been given by Purchaser, any changes in design, material and method of manufacture shall be notified to Purchaser whose approval in writing of all changes shall be obtained before the valve is manufactured. 9.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one reproducible and six copies of all approved drawings, documents and specifications as listed in clause 9.2 above. Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the following: a) b) Test certificates as listed in clause 6.0 of this specification. Manual for installation, erection, maintenance and operation instructions including a list of recommended spares for the valves.

9.4

All documents shall be in English language only.

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ABOVE GROUND INSTALLATION

UNDER GROUND INSTALLATION

FIGURE- 4.6

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SPECIFICATION FOR GAS POWERED VALVE ACTUATORS

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TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

SCOPE REFERENCE DOCUMENTS ACTUATOR SIZING DESIGN FEATURES COATING INSPECTION AND TESTS NAME PLATE SHIPPING DOCUMENTATION SPARES AND ACCESSORIES

ATTACHMENTS - SKETCH-I - SKETCH-2 - GAS COMPOSITION

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1.0 SCOPE 1.1 This specification, together with the applicable data sheet, covers the minimum requirements for the design, manufacture, inspection, testing and shipping of valves actuators complete with accessories for quarter tarn ball valves. This specification indicates the minimum supply requirements and does not relieve the vendor from his responsibilities concerning the design and the safe operation of the supplied equipment. The valve manufacturer shall also be responsible or proper operation of the actuator that shall develop a torque or a thrust sufficient to conveniently open aid close the valve always with in the limits established by the resistance of the mechanical elements of the valve itself. Valve and actuator shall be supplied as a single assembly co in all respect and ready for installation at site. 2.0 REFERENCE DOCUMENTS Reference is made in this specification to the latest edition of the following ea: standards and specifications: Codes and Standards a. ASME B31.8 b. ASME B 16.5 c. d. ASME B16.47 ASME SEC. VIII : : : : : : : : Gas Transmission and Distribution Piping System: Pipe flanges and Hanged Fittir Large dia Steel Flanges NPS 26 through N PS 60 Boiler and Pressure Vessels Code. Pipe Threads, General Purpose National Electric Code International, Electrotechnical commission National Electrical Manufacturers Association

1.2

13

1.4

e. ANSI B2. I f. NEC g. IEC h. NEMA

Purchaser Specification S-04-02-007 Standard Specification for Ball Valves (Onshore)


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In case of conflict between the requirements of this specification and above referred documents, the requirements of this specification shall govern. 3.0 ACTUATOR SIZING 3.1 For sizing the actuator, Valve manufacturer shall fl to the actuator manufacturer the following information: a) The maximum break-away torque or thrust required at the valve stem with manual/ remote operation to open and close a valve at the shut off pressure in the line. The actuator shall be sized at 10 kg/cm2(g) gas pressure and meeting the safety factor of 1.25 as required by the valve operation at the maximum differential pressure corresponding to valve class rating. b) The temperature correction factor. c) The pressure correction factor. d) As a result of points (a) to (c) the minimum required torque or thrust output of the actuator. e) Maximum allowable torque or thrust output of the actuator depending on the type and size of valve. 3.2 3.3 3.4 Actuator manufacturer shall provide the complete model no. decoding for actuators, limit switches and solenoid valves. Complete details of Gas/Hydraulic circuit with complete sequencing of port fro open to close and close to open position shall be furnished in the offer for review. Manufacturer shall furnish the detailed calculation for actuator sizing after placement of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria as per above clauses. Manufacturer shall agree to upgrade the actuators offered to meet the sizing criteria without any price and schedule impact. Manufacturer shall furnish the detailed calculation for actuator sizing after placement of order. The calculation so furnished by manufacturer shall satisfy the sizing criteria as per above clauses. Manufacturer shall agree to upgrade the actuators offered to meet the sizing criteria without any price and schedule impact.

3.5

4.0 DESIGN FEATURES 4.1 The actuator shall be powered by Natural Gas from the main pipeline. The gas powered actuator shall operate at 10 kg/cm (g). A typical scheme for tapping the gas
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from mainline with pressure reduction is shown in SKETCH-1. Actuator electrical/ hydraulic circuit shall he developed as per the SKETCH-2 enclosed. 4.2 Actuator shall be direct gas operated scotch yoke or rotary vane type with manual hydraulic override. The actuator shall he provided with a hydraulic pump or manual operation If there is no gas pressure available to actuator it shall be possible to actuate Direct Pneumatic Actuator by means of Nitrogen bottles or similar pressure source. Actuator: manufacturer shall furnish the capacity and set pressure of nitrogen bottles for at least two opening and two closing stroke of the actuator. The actuator shall be suitable for gas operating conditions and ambient temperature as specified in data sheets. The presence of methanol in the gas shall not affect the service of the Actuator. All materials in contact with natural gas shall he suitable for the gas composition attached with this specification. The actuator and its accessories shall be suitable for outdoor installation and have weather proof enclosure as per IP 55 as a minimum. In addition alt compartments and housing containing electrical devices such as switches, contactors, relay, fuses, terminal box, glands etc. shall be flame proof suitable for IEC Zone-I, Gas Gr. II A & II B, Temp. Class 13 or equivalent. The cable gland shall be 1 NPT thread. The unused cable entries must he plugged off with solid metal plug. Solenoid valves shall be of flame proof design certified for IEC Zone-1, Gas Gr. II A & II B, Temp. Class 13 or equivalent with moulded continuous duty coils and stainless steel valve body. Vendor shall furnish hazardous area certificates for the above items certified by a Statutory body such as FM, UL, BASEEFA, PTB etc. In addition for above electrical items/ instruments supplied for projects in India, approval from CCE (Chief Controller of Explosive) shall be furnished, irrespective of the place of manufacture and the same is mandatory. In case CCE certificate is not available now for any item, vendor to confirm that the same shall he furnished before shipment. 4.6 4.7 All pressure containing parts shall be designed to ASME Section VIII. a) The actuator shall be suitable for direct mounting to the valve without changing the standard top works of the valve and shall have the capability to but mounted or removed from the valve when the valve is in service, The actuators shall he flanged and bolted directly on the valve body or extension. The connection between actuator and the valve or between the operator, the outer casing of the extension and the valve shall be such that there is no
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4.3

4.4 4.5

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movement between these connections when the valve is actuated by the actuator under any load. b) 4.8 4.9 Actuator shall be suitable for installation on a vertical stem unless otherwise specified in the data sheet.

Provision shall be made to prevent accidental pressure build up in the actuator. The construction of the actuator and its controls shall be such that proper manual operation and maintenance can be carried out by skilled personnel without the risk of being injured e.g. by moving parts. A position indicator on the actuator shall show the valve in the open, closed or partially open positions. Bearings shall be factory packed with grease and shall not require additional lubrication for the life of the actuator. Unless specified otherwise in the data sheet, the actuator be equipped with limit valves which immediately shut off the gas supply to actuator when the valve reaches one of its end positions. Actuator shall be provided with pressure gauges for pneumatic and hydraulic systems. The pressure gauges for the hydraulic system shall be in circuit with the pressure relief system. In selection of pressure regulator due consideration shall be given to the effect of cooling of gas at the regulator and its down stream section, A high pressure dehydrating fiter cartridge shall be provided to remove condensate, moisture, foreign particles and any corrosive contaminants from pipeline gas. The sound level of the gas escaping into the atmosphere when the actuator is in operation shall not exceed 90 dBA, measured at a distance of 1 meter. The actuator shall be operated by either of the following two methods: a) For the remote control, the actuator shall have a solenoid valve, limit switches, relays, etc. and shall be suitable for remote and local operation as per description in the attached Actuator Data Sheet(s). Electrical signal supplied is a momentary type with 1sec duration signal. Actuator shall have a self retaining system of the above signal in its control circuit.
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4.10 4.11 4.12

4.13

4.14 4.15 4.16 4.17

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b)

For the local-control the actuator shall be suitable for local operation with line gas feed lines or through nitrogen bottles. The devices and accessories, which do not require the electricity for their operation, shall be provided in the actuators as per P this specification. The actuator shall have a hand pump in conjunction with the oil circuit to achieve local control with hydraulic shock functionality. The actuators shall be provided with limit switches for open and close positions. The position of switches shall be adjustable near the valve open and close positions. The limit switches shall be wired upto terminal block and shall be numbered for proper identification. The limit switches shall have 2 sets of contacts for each open and close position. The contact rating shall be as specified in the data sheet. The power solenoid valves shall he cut-off when the actuator has travelled to extreme positions (close and open). The limit switches shall he wired in the actuator control circuit by the vendor so as to cut off power to die actuator once the end positions of the valve are reached. This is required to dc-energize the solenoid valves in the steady state condition and failure of electrical power will not affect the valve position.

4.18

a)

b)

4.19 4.20 4.21

The stroke of the Actuator shall he easily adjustable in steps of maximum 0.5 for Ball Valves. Speed control nozzles for adjusting the valve speed over a wide range shall be provided. If remote control is required, a lock/ remote switch shall be installed to prevent remote control during maintenance work. This switch shall be provided with a hole 12 mm in diameter for locking with pad lock in either position. This local/ remote switch shall be wired upto the junction box as per circuit diagram. All control accessories, pneumatic and hydraulic, shall be mounted in an enclosure and shall be fully wired and tubed. The enclosure shall he weatherproof as per IP 55 9or equivalent. All bleed and vent connections wherever required shad be piped outside the actuator cabinet so as to prevent gas pocketing inside the actuator cabinet. The actuator will be of an automatic self purging design such that any gas pocket in the actuator will be eliminated. Vendor shall be responsible for integrating the potential free NO or NC contacts of Remote Telemetry Unit (RTUs) for open and close command in interlock circuit. These commands will be of momentary type with 1 sec duration.

4.22

4.23

4.24

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4.25 4.26

All mounting accessories needed for installing the actuator, tanks etc. are in manufacturers scope of supply. The interconnecting cabling, interconnecting pipe work between the actuator and the valve, adapters, tubing, cable glands, junction box are in manufacturers scope of supply. The actuator shall be supplied totally self-contained, wired, tubed and mounted on ball valve. In case of a separate control box, wiring and tubing between control box and actuator is in the vendors scope. Three metres of 3/4 tubing set including all connectors between the actuator and the control box and three metres of interconnecting piping work upstream & downstream of the valve and the control box shall be provided. Owner shall provide 20 mm (3/4) SW tapping on process main line for line gas tapping. Threading connections shall be NPT as per ANSI B 2.1 and flange connection as ANSI B 16.5/ANSI B16.47. The tubing, fitting and valves shall be stainless steel with Swage Lock fitting or equivalent. COATING

4.27

4.28

5.0

The actuator. including gear boxes and piping, shall be coated as described below: 5.1 5.2 Removal of all rust by means of emery cloth or wire brush. Shot blast as per Swedish Standard No. SIS 055900 latest edition SA 2.5 one layer PrimerEpoxyPolyamide DET 75 microns intermediate layer Epoxv-Polyamide DFT 25 microns, final layer Epoxy- Polyamide DFT 75 microns. Total DFT 175 microns and color RAL 5012 (light blue). INSPECTION AND TESTS Test at the Actuator Manufacturers Shop a) Electrical and mechanical operating tests. b) Seal test or hydraulic circuits. c) Check of required functions. d) Check of operating time control. e) Check of limiting device operation. f) Check of the actuator torque or thrust.
SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR GAS POWERED VALVE ACTUATORS S 04 02 012 REV - 0 Page 8 of 14

6.0 6.1

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6.2

Test at the Valve Manufacturers Shop a) Test and check covered by point 6.1 after assembly with ball/plug valve. b) No load test (DP=0) or load (DP max) Operations with the minimum required feeding pressure (10 kg/cm) c) Check of the limiting device operation. d) Various tests on the valve according to provisions of specific documentation. e) Testing shall conform to actual field operating conditions.

6.3 6.4 6.5

All actuators shall be visually inspected. Dimensional check on actuators shall be carried out as per the Purchaser approved drawings. Purchaser reserves the right to perform inspection as indicated above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Purchasers Inspector. In no case shall any action of Purchaser or his inspector relieve the Manufacturer of his responsibility for material design, quality or operation of actuators.

7.0

NAMEPLATE

Actuator shall have a SS name plate attached firmly to it at a visible place and reporting the following information: a) Instrument tag number as per Purchasers data sheets.

b) Manufacturers model, trade mark, serial no. etc. c) Max. allowable operating pressure or voltage. d) Area Classification in which the equipment can be used. e) Actuator characteristics data f) Inspection agency name or logo 8.0 SHIPPING

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8.1 8.2 8.3 8.4

All threaded and flanged opening shall be suitably protected to prevent entry of foreign material. The actuator shall be supplied pre-assembled except piping/ tubing, actuator, actuator control unit, tanks and other accessories shall be packed separately. Protective grease oil coating shall be applied on the surface to protect them from rusting. Package shall be marked legibly with suitable marking ink the following: a) Order number b) Package number c) Manufacturers name d) Model No. & Thrust e) Tag number f) Inspection agency name or logo

9.0 9.1

DOCUMENTATION At the time of bidding the manufacturer shall submit the following documents in accordance with EN10204 3. IC:

a) A detailed specification sheet for valve actuator providing all the details regarding type, materials of construction for various parts etc. b) Schematic diagrams showing the complete actuator control circuit. c) A detailed dimensional drawing. d) Installation drawing complete with valve assembly. e) Actuator sizing calculations including relation between required toque of valve and actuator output torque. f) Information asked for vide section 3.0 of this specification and actuator sizing as per Actuator Data Sheet. g) Drawing showing connections by Purchaser (piping, electrical etc.)
SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR GAS POWERED VALVE ACTUATORS S 04 02 012 REV - 0 Page 10 of 14

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h)

Wiring diagram (actuator electrical circuitry) incorporating latching of momentary signals, remote/ local switch, and limit switches.

i) Junction box terminal block nos. for I/O signals. j) Parts list. k) Recommended spare parts with prices. l) Assembly details (Valve & Actuator). m) Clause wise List of deviations from this specification, if any n) Information regarding the past experience on similar actuators including (a) Size (b)Numbers (c) Name of Installation (d) Owner (e) Name of Contact Person (f) Date of Installation. o) Technical Catalogue giving detailed technical specification and other information for each type of actuator and its accessories covered in the bid. 9.2 Within 30 days from the date of Purchase Order manufacturer shall submit copies of the following for Purchasers review and approval. a) Documents and specifications as listed in Cause 9.1 of this specification. b) Test certificates and certificates from statutory bodies. c) Manual for installation, erection instructions, maintenance and operation instructions. d) Complete assembly drawing of the ball valve matching with the actuator offered. The approval of these drawings/ documents will not absolve vendor of the responsibility with respect to correct operation of the actuator. Manufacturers quotation, catalogues, drawings, operating and maintenance manuals etc. shall be in English language. 10.0 SPARES AND ACCESSORIES 10.1 10.2 10.3 Manufacturer shall furnish list of recommended spares and accessories for actuators required during start-up and commissioning. Manufacturer shall furnish list of recommended spares and accessories required for two years of normal operation and maintenance of actuators. Manufacturer shall quote for spares and accessories as per Material Requisition.
SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR GAS POWERED VALVE ACTUATORS S 04 02 012 REV - 0 Page 11 of 14

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1. Stop Valve (3/4 NPT), 2. Check Valve, 3. High Pressure Shuttle Valve, 4. Filter Separator & Gas Dehydrator, 5. Self Actuated Pressure Regulator, 6. Safety Relief Valve Notes : The Scheme shows outline of Power Gas Feeding System., Vendor shall develop and supply the suitable system in accordance with the specification.

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SPECIFICATION NO. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR GAS POWERED VALVE ACTUATORS S 04 02 012

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GAS COMPOSTION

SL. NO

PARAMETER

RELIANCE

R-LNG

SPOT

Lean gas at Vijaipur

Typical Mole (%) 1 2 3 4 5 6 7 Methane (C1) Ethane(C2) Propane(C3) T-Butane(C4) T-Pentane(C5) Hexane(C6) Carbon Di-oxid C O 2 8 Nitrogen (N2) Total Sulphur content H2S 0 NA NA 0.19 24 ppmw 6ppmw 0.11 24 ppmw 6ppmw 0.11 94.0 5.0 1.0 0.00 0.00 88.51 7.72 2.33 1.18 0.07 92.79 5.41 1.37 0.32 90.84 5.02 0.68 0.05 3.30

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STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES


SIZE UP TO DN 400 mm (16)

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16)

SPECIFICATION S 04 02 013

REV-0 Page 1 of 7

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CONTENTS

Sl. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

Description SCOPE REFERENCE DOCUMENTS MANUFACTURERS QUALIFICATION MATERIALS DESIGN AND MANUFACTURE INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT DOCUMENTATION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16)

SPECIFICATION S 04 02 013

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1.0

SCOPE This specification covers the minimum requirements for the design, manufacture and supply of following carbon steel flanges and fittings of size upto DN 400 mm (16) to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG): Flanges such as welding neck flanges, blind flanges, spectacle blinds, spacers and blinds etc. Seamless fittings such as tees, elbows, reducers, caps, outlets etc.

This specification does not cover the above-mentioned items, which are to be installed in pipeline systems handling sour hydrocarbons (liquid/gas) service as defined in NACE Standard MR-01-75 2.0 2.1 REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition of the following Codes: ASME B31.4 - Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids ASME B31.8 - Gas Transmission and Distribution Piping Systems ASME B16.5 - Pipe Flanges and Flanged Fittings ASME B16.9 - Factory Made Wrought Steel Butt Welding Fittings ASME B16.11 - Forged Steel Fittings, Socket Welding and Threaded ASME B16.48 - Steel Line Blanks ASME Sec VIII/IX - Boiler and Pressure Vessel Code ASTM A370 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges and Unions MSS-SP-44 - Steel Pipeline Flanges. MSS-SP-75 - Specification for High Test Wrought Welded Fittings. MSS-SP-97 - Forged Carbon Steel Branch Outlet Fittings-Socket Welding, Threaded and Butt welding Ends.
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2.2

In case of conflict between the requirements of this specification and the requirements of above referred Codes and Standards, the requirements of this specification shall govern. MANUFACTURERS QUALIFICATION Manufacturer who intends bidding for fittings must possess the records of a successful proof test, in accordance with the provisions of ASME B 16.9.

3.0

4.0 4.1

MATERIAL The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed. Material for flanges and fittings shall comply the material standard indicated in the Purchase Requisition. In addition, the material shall also meet the requirements specified hereinafter. Each heat of steel used for the manufacture of flanges and fittings shall have Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the following formula:

4.2

4.3

For flanges and fittings specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, Charpy V-notch test shall be conducted on each heat of steel. Unless specified otherwise, the Charpy V-notch test shall be conducted at 00 C in accordance with the impact test provisions of ASTM A- 370 for flanges and fittings. The minimum average absorbed impact energy values of three full-sized specimens shall be 27 joules. The minimum impact energy value of any one specimen of the three specimens analyzed as above shall not be less than 80% of the above mentioned average value. For flanges and fittings specified to be used for other hydrocarbon service, the Charpy V-notch test requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable material standard shall be complied with.

4.4

For flanges and fittings, specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out in accordance with ASTM A 370. Hardness testing shall cover at least 10% per item, per size, per heat, per manufacturing method. A full thickness cross section shall be taken for this purpose and the maximum hardness shall not exceed 248 HV10. For flanges and fittings, specified to
GAIL (INDIA) LTD NEW DELHI STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16) SPECIFICATION S 04 02 013 REV-0 Page 4 of 7

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be used for other hydrocarbon services, the hardness requirements stated above are not applicable. 4.5 5.0 5.1 5.2 5.3 In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. DESIGN AND MANUFACTURE Flanges such as weld neck flanges and blind flanges shall conform to the requirements of ASME B16.5. Spectacle blind and spacer & blind shall conform to the requirements of ASME B16.48. Fittings such as tees, elbows, reducers, etc. shall be seamless type and shall conform to ASME B 16.9 for sizes DN 50 mm (2) and above and ASME B16.11 for sizes below DN 50 mm (2). Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in accordance with MSS-SP-97. Type, face and face finish of flanges shall be as specified in Purchase Requisition. Flanges and fittings manufactured from bar stock are not acceptable. All butt weld ends shall be bevelled as per ASME B16.5/ ASME B16.9/MSS-SP-97 as applicable. Repair by welding on flanges and fittings is not permitted. INSPECTION AND TESTS The Manufacturer shall perform all inspections and tests as per the requirement of this specification and the relevant codes, prior to shipment at his works. Such inspections and tests shall be, not but limited to the following:

5.4 5.5 5.6 5.7 5.8 6.0 6.1

6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the fittings shall be free from any strikes, gauges and other detrimental defects. 6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 for flanges, ASME B16.48 for spacers and blinds and ASME B16.9/ MSS-SP-97 as applicable for fittings and as per this specification. 6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16)

SPECIFICATION S 04 02 013

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6.1.4 All finished wrought weld ends subject to welding in field, shall be 100% tested for lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall not be acceptable. 6.2 Purchasers Inspector reserves the right to perform stage wise inspection and witness tests, as indicated in clause 6.1 of this specification at Manufacturers Works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide, without charge, reasonable access and facilities required for inspection, to the Purchasers Inspector. Inspection and tests performed/ witnessed by Purchaser s Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests. 7.0 TEST CERTIFICATES Manufacturer shall furnish the following certificates: a) Test certificates relevant to the chemical analysis and mechanical properties of the materials used for manufacture of flanges and fittings as per relevant standards and this specification. Test Reports on non destructive testing. Certificates for each fitting stating that it is capable of withstanding without leakage a test pressure, which results in a hoop stress equivalent to 100 % of the specified minimum yield strength for the pipe with which the fitting is to be attached without impairment of serviceability.

b) c)

8.0 8.1

PAINTING, MARKING AND SHIPMENT After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection against corrosion during transit and storage. The coating shall be easily removable in the field. Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for fittings and flanges. Flange face shall be suitably protected to avoid any damage during transit. All flanges and fittings shall be marked as per applicable dimension/manufacturing standard.

8.2

8.3

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16)

SPECIFICATION S 04 02 013

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9.0 9.1 9.2

DOCUMENTATION Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in clause 7.0 of this specification. All documents shall be in English Language only.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SEAMLESS FITTINGS & FLANGES (UPTO 400 mm/ 16)

SPECIFICATION S 04 02 013

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STANDARD SPECIFICATION FOR FLANGES & WELDED FITTINGS (SIZE DN 450 mm (18") AND ABOVE)

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE

DOCUMENT NO. S-04-02-014

REV-0 Page 1 of 7

Copyright GAIL All rights reserved

CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 SCOPE REFERENCE DOCUMENTS MANUFACTURER'S QUALIFICATION MATERIALS DESIGN AND MANUFACTURE INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT DOCUMENTATION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE

DOCUMENT NO. S-04-02-014

REV-0 Page 2 of 7

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1.0

SCOPE:

This specification covers the minimum requirements for the design, manufacture and supply of following carbon steel flanges and fittings of size DN 450 mm (18") and above to be installed in pipeline systems handling hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG): Flanges such as weld neck flanges, blind flanges, spectacle blinds, spacers and blinds, etc. Welded fittings such as tees, elbows, reducers, caps, outlets etc.

This specification does not cover the above-mentioned items, which are to be installed in pipeline systems handling sour hydrocarbons (liquid / gas) service as defined in NACE Standard MR-01-75. 2.0 2.1 REFERENCE DOCUMENTS: Reference has been made in this specification to the latest edition of the following Codes, Standards and Specifications. ASME B31.3 ASME B31.4 ASME B31.8 ASME B16.5 ASME B16.9 ASME B 16.25 ASME B16.47 ASME B16.48 ASME Sec VIII/IX ASTM A370 MSS-SP-25 MSS-SP-44 MSS-SP-75
GAIL (INDIA) LTD NEW DELHI

Process Piping Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids Gas transmission and distribution piping system Pipe Flanges and Flanged fittings Factory made wrought steel Butt welding fittings Butt welding Ends Large diameter steel Flanges Steel line Blanks Boiler and Pressure Vessel code Standard test methods and Definitions for mechanical testing of Steel products Standard Marking system for Valves, Flanges, Fittings and Unions Steel Pipeline Flanges Specification for high Test Wrought Welded fittings
DOCUMENT NO. S-04-02-014 REV-0 Page 3 of 7

STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE

Copyright GAIL All rights reserved

MSS-SP-97

Forged Carbon Steel Branch Outlet Fittings- Socket Welding, Threaded and Butt Welding Ends

2.2

In case of conflict between the requirements of this specification and the requirements of above referred Codes and Standards, the requirements of this specification shall govern. MANUFACTURER'S QUALIFICATION:

3.0

Manufacturer who intends bidding for fittings must possess the records of a successful proof test in accordance with the provisions of ASME B16.9 / MSS-SP-75, as applicable. 4.0 4.1 MATERIAL: The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed. Material for flanges and fittings shall comply the material standards indicated in the Purchase Requisition. In addition, the material shall also meet the requirements specified hereinafter. Each heat of steel used for the manufacture of flanges and fittings shall have Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the following formula: CE 4.3 = C + Mn + Cr+ Mo + V + Ni+Cu 6 5 15

4.2

For flanges and fittings specified to be used for Gas service or High Vapour Pressure (WP) liquid service, Charpy V-notch test shall be conducted on each heat of steel. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0' C in accordance with the impact test provisions of ASTM A 370 for flanges and MSS-SP-75 for all fittings. The minimum average absorbed impact energy values of three full-sized specimens shall be 27 joules. The minimum impact energy value of any one specimen of the three specimens analysed as above, shall not be less than 80% of the above mentioned average value. For flanges and fittings specified to be used for other hydrocarbon service, the Charpy V-notch test requirements as stated above are not applicable, unless required by the specified material standard as a mandatory requirement. When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition for flanges and fittings, the Charpy V-notch test requirements of applicable material standard shall be complied with.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE

DOCUMENT NO. S-04-02-014

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4.4

For flanges and fittings, specified to be used for Gas service or High Vapour Pressure (HVP) liquid service, hardness test shall be carried out as per ASTM A 370 for each heat of steel used. A full thickness cross section shall be taken for this purpose and the maximum hardness of base metal, weld metal and heat affected zone shall not exceed 248 HV10. For flanges and fittings, specified to be used for other hydrocarbon services, the hardness requirements stated above are not applicable.

4.5 5.0 5.1

In case of RTJ flanges, the groove hardness shall be minimum 140 BHN. DESIGN AND MANUFACTURE: Flanges such as weld neck flanges and blind flanges shall conform to the requirements of ASME B16.5 up to sizes DN 600 mm (24") excluding DN 550 mm (22'9, and MSS-SP-44 for sizes DN 550 mm (22") and ASME B16.47 (Series A) for sizes DN 650 mm (26") and above. Spectacle blind and spacer & blind shall conform to the requirements of ASME B 16.48 up to sizes DN 600 mm (24"). For sizes DN 650 mm (26") and above, spectacle blind and spacer & blind shall conform to Manufacturer's standard. Type, face and face finish of flanges shall be as specified in Purchase Requisition. Fittings such as tees, elbows, reducers, etc. shall be either welded or seamless type. All fittings shall comply with the requirements of MSS-SP-75. Fittings such as weldolets etc. shall be manufactured in accordance with MSS-SP97. Tees shall be manufactured by forging or extrusion method. Stub-in or pipe to pipe connection shall not be used in the manufacture of tees. The longitudinal weld seam shall be kept at 90 degree from the extrusion. Fittings shall not have any circumferential weld joint. All butt weld ends shall be beveled as per ASME B16.5 / MSS-SP-44 / ASME B16.47 as applicable for flanges and MSS-SP-75/MSS-SP-97 as applicable for fittings. The reinforcement of inside weld seam shall be removed for a distance of 100mm from each end of welded fittings. All welds shall be made by welders and welding procedures qualified in accordance with provisions of ASME Sec. IX. The procedure qualification shall include Charpy V-notch test for weld heat affected zone and hardness test in accordance with clause 4.3 and 4.4 of this specification respectively. Repair by welding on flanges and parent metal of fittings is not permitted. Repair of weld seam by welding shall be carried out by welders and welding procedures duly qualified as per ASME Section IX and records for each repair shall be
GAIL (INDIA) LTD NEW DELHI STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE DOCUMENT NO. S-04-02-014 REV-0 Page 5 of 7

5.2

5.3 5.4 5.5 5.6

5.7 5.8 5.9

5.10

Copyright GAIL All rights reserved

maintained. Repair welding procedure qualification shall include all tests, which are applicable for regular production welding procedure qualification. 6.0 6.1 INSPECTION AND TESTS: The Manufacturer shall perform all inspections and tests as per the requirement of this specification and the relevant codes, prior to shipment at his works. Such inspections and tests shall be, not but limited to the following:

6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the fittings shall be free from any strikes, gauges and other detrimental defects. 6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 / MSS-SP-44 / ASME B16.47 as applicable for flanges, ASME B 16.48 for spacers and blinds and ASME B 16.9 / MSS-SP-75/MSS-SP-97 as applicable for fittings and as per this specification. 6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. 6.1.4 The non-destructive inspection shall be carried out as given below: a) b) All butt and repair welds for welded fittings shall be examined 100 % by radiography. Acceptance criteria shall be as be ASME B 31.4 or ASME B 31.8 as applicable and API 1104. When elbows of size 18" NB 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. All finished wrought weld ends subject to welding in field, shall be 100% tested for lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall not be acceptable. Magnetic particle or liquid penetrant examination shall be performed on cold formed butt welding tees with extruded outlets (that are subjected to an extreme fibre elongation of greater than 5 %) as per the Supplementary Requirement SR 3 of MSS-SP-75. 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 12 and Appendix 6 respectively.

c)

d)

e)

6.2

Purchaser's Inspector reserves the right to perform stage wise inspection and witness tests, as indicated in clause 6.1 of this specification at Manufacturer's Works prior to shipment. Manufacturer shall give reasonable notice of time and
STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE DOCUMENT NO. S-04-02-014 REV-0 Page 6 of 7

GAIL (INDIA) LTD NEW DELHI

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shall provide, without charge, reasonable access and facilities required for inspection, to the Purchaser's Inspector. Inspection and tests performed/witnessed by Purchaser's Inspector shall in no way relieve the Manufacturer's obligation to perform the required inspection and tests. 7.0 TEST CERTIFICATES:

Manufacturer shall furnish the following certificates: a) Test certificates relevant to the chemical analysis and mechanical properties of the materials used for manufacture of flanges and fittings as per relevant standards and this specification. Test Reports on radiography, ultrasonic inspection and magnetic particle examination. Test reports of heat treatment carried out as per the specification. Welding procedures and welders qualification reports. Certificate for each fitting stating that it is capable of withstanding without leakage a test pressure, which results in a hoop stress equivalent to 100% of the specified minimum yield strength for the pipe with which the fitting is to be attached without impairment of serviceability. PAINTING, MARKING AND SHIPMENT: After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill coating for protection against corrosion during transit and storage. The coating shall be easily removable in the field. Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage during transit. Metallic or high impact plastic bevel protectors shall be provided for flanges and fittings. Flange face shall be suitably protected to avoid any damage during transit. All flanges and fittings shall be marked as per applicable dimension / manufacturing standard. DOCUMENTATION: Prior to shipment, the Manufacturer shall submit six copies of the test certificates as listed in clause 7.0 of this specification. All documents shall be in English Language only.

b) c) d) e)

8.0 8.1

8.2

8.3 8.4 9.0 9.1 9.2

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR FLANGES &WELDED FITTINGS (SIZE 450 MM (18) AND ABOVE

DOCUMENT NO. S-04-02-014

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STANDARD SPECIFICATION FOR LR BENDS

FOR ONSHORE PIPELINES

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR LR BENDS FOR ONSHORE PIPELINE

SPECIFICATION S 04 02 015

REV- 0 Page 1 of 10

Copyright GAIL All rights reserved

CONTENTS
1.0 2.0 3.0 4.0 6.0 7.0 8.0 9.0 SCOPE REFERENCE DOCUMENTS MATERIAL INSPECTION AND TESTS TEST CERTIFICATES MARKING, PACKING AND SHIPMENT DOCUMENTATION BEND MANUFACTURING PROCEDURE QUALIFICATION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR LR BENDS FOR ONSHORE PIPELINE

SPECIFICATION S 04 02 015

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1.0

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 or liquid phase including Liquified Petroleum Gas (LPG).

2.0

REFERENCE DOCUMENTS 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 specififcations: a) ASME 31.4 : Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids. : Gas Transmission and Distribution Piping System : Specification for High Test Wrought Welding Fittings

b) ASME B 31.8 c) d) MSS-SP-75

Purchaser specification of Line pipes

In case of conflict between the requirement of above reference documents and this specification; the requirements of this specification shall govern. 3.0 3.1 MATERIAL Bends shall be fabricated from steel line pipe. The type of pipe to be used for fabrication of bends shall be indicated in the Work Order. Pipe with positive wall thickness tolerances shall be used for fabrication of bends. Unless specified otherwise in the Work Order, the line pipes for fabrication of bends shall be procured by Owner. Heat treatment shall be carried out for all finished bends inn 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 2.0. 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. Mechanical testing of test bends performed during the bend manufacturing procedure qualification as per section 9.0 of this specification, shall ensure that all bends made according to the Company approved bend manufacturing procedure have the required mechanical properties and destructive testing of production bend
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3.2 3.3

3.4

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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. 4.0 4.1 MANUFACTURE Material grade, bend size, bend radius an 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. 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. When bending SAW or Electric Welded 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. 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. Unless otherwise specified differently in the PO, the bevels at the ends shall be as per the relevant pipe specification. Bends shall not have any circumferential joint. No repair by welding is allowed on any part of the bends. 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. 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. 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 2.0. 4.10.1 Following tolerances shall be applicable for Bend Angle and Bend Radius:
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4.2

4.3

4.4 4.5 4.6 4.7 4.8

4.9 4.10

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Bend Angle Bend Radius

: 0.50 from the specified angle : 1 % of bending nominal radius (radius as indicated in clause 4.1 above).

4.10.2 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 where: tactual = Actual wall thickness of pipe used for bending t = 0.35 mm for a wall thickness < 10 mm 0.5 mm for a wall thickness 10 mm 4.9.3 Out of roundness tolerance on the body and ends of the bend shall be as follows: Body Measurement of the outside diameter shall be taken in plane of the bend at locations where wrinkles are present (ODmax.) and at locations where wrinkles are not present (ODmin). Out of roundness shall be considered acceptable, if the value of ((ODmax. - ODmin)/ ODnom) does not exceed 2.5%. The measurements shall be made over the circumference of the bend either at distances approximately equal to pipe diameter or 300 mm whichever is less. Minimum three measurements shall be taken for each bend. Ends Out-of-roundness over a length of 100 mm from the end shall comply with the requirements of relevant company specification. 4.9.4 Off-Plane Off-Plane of bends shall not exceed (/ 90) X 10 mm, where 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. 5.0 INSPECTION & TESTS
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0.95 (tactual - t)

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5.1

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 Manufactures shop is in full compliance with the pipe specification as referred in clause 2.0 of this specification. Visual inspection Dimensional and tolerances check as per MSS-SP-75 and requirements of Section 4.0 of this specification. Check heat treatment, if carried out, as required and maintain its records. Temperature against time recorder charts for each induction heating. 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 and seam welds of bends manufactured from EW pipe shall be 100% ultrasonically tested. The acceptance criteria shall be relevant pipe specification. The full circumference of both ends of each bend after beveling 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. VII Appendix 6. 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. Companys Inspector reserves the right to perform stage wise inspection and witness tests on all bends as indicated in Clause 5.1 at Manufacturers works, prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection, to the Companys Inspector. Inspection and tests
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b) c) d) e) f)

g)

5.2

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performed or witnessed by Companys Inspector shall in no way relieve the Manufacturers obligation to perform the required inspection and tests. Under no circumstances any action of the Companys Inspector shall relieve the Manufacturer of this responsibility for the material and quality of bends. 6.0 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) c) d) e) Certificates of non-destructive test/ examination carried out on bends. Records of heat treatment, ifcarried out for bends. Certified reports of dimensional tolerance of bends. Certificates of all other tests as required in this specification.

The Certificate shall be valid only when signed by Companys Inspector. Only those bends which have been certified by Companys Inspector shall be dispatched from Manufacturers works. 7.0 7.1 7.2 7.3 7.4 7.5 MARKING, PACKING AND SHIPMENT All bends shall be marked as per MSS-SP-75. All loose and foreign material like rust, grease, etc. shall be removed from inside and outside of the bends. 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. 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. Package shall be marked legibly with suitable marking ink to indicate the following: a) b) Order Number Package Number
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c) d) e) 8.0

Manufacturers Name Size (Inches) and Wall thickness (mm) Radius of bend (mm)

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 CONTRACT document.

8.1 8.2

All documents shall be in English language At the time of bidding, bidder shall submit the following documents: a) b) Reference list of previous supplies of bends of similar specifications. Brief description of manufacturing including heat treatment and quality control facilities of the Manufacturers Works.

8.3

Within three weeks of placement of order, the manufacturer/ contractor shall submit bend manufacturing procedure including manufacturing, inspection, testing procedures, quality control manual and quality plans. The bend Manufacturing Procedure shall detail the following, as a minimum: a) b) c) d) e) f) g) h) Sequence of Operation Induction forming process including bending temperature, temperature control, bending Rate , cooling rate and cooling procedure. Temperature measurement and calibration. Post bend heat treatment procedure including temperature and time. Dimensional control procedure. Pipe material used for bend manufacture NDT procedures Quality Control and Quality Plans

Upon successful completion of the bend manufacturing procedure qualification as per section 9.0 of this specification, Manufacturer shall submit the qualified procedure to company for approval. Regular production of bends shall commence

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STANDARD SPECIFICATION FOR LR BENDS FOR ONSHORE PIPELINE

SPECIFICATION S 04 02 015

REV- 0 Page 8 of 10

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only after the bend manufacturing procedure has been qualified and approved by company. 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. 8.4 8.5 9.0 9.1 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. Prior to shipment, the Manufacturer shall submit test certificates as listed in section 6.0 of this specification. BEND MANUFACTURING PROCEDURE QUALIFICATION 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. Test bends shall be made by using the pipe specified in clause 2.0 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. Inspection and Testing of Bends

9.2

9.3

9.3.1 All finished test bends shall meet the requirement of dimensional tolerances, inspection and non-destructive testing requirements specified in section 4.0 & 5.0 of this specification. 9.3.2 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 linepipe specification. Test procedure and acceptance criteria shall be in accordance with the relevant linepipe 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 450 mm (18) NB and larger, the specimen shall be taken at inside radius and one at outside radius of bend.
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b)

All Weld Tensile Test In case of bends fabricated from SAW Ppipes, 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 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 specimen 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.

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 450 mm ( 18) NB and larger, the base material specimens shall be taken at the outside radius of the bend.

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 clause 8.3, tolerances on various controlling parameters.

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STANDARD SPECIFICATION FOR LR BENDS FOR ONSHORE PIPELINE

SPECIFICATION S 04 02 015

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STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)

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STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)

DOCUMENT NO. S-04-02-016

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CONTENTS
Sl. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 Description SCOPE REFERENCE DOCUMENTS MATERIALS & REQUIREMENTS MANUFACTURE QUALIFICATION AND PRODUCTION TESTING INSPECTION AND TESTS COATING / PAINTING MATERIAL TESTING AND TRACEABILITY PREPARATION FOR SHIPMENT MARKING VENDOR DATA REQUIREMENT DESIGN OF BARRED TEE

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STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)

DOCUMENT NO. S-04-02-016

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1.0

SCOPE:

This specification covers the basic technical requirements for design, manufacture, inspection, testing, coating and painting & supply of Pipeline Flow Tees (Barred Tees) (above ground / under ground) to be installed in pipeline system transporting Natural Gas. All Tees shall be suitable for Bi-directional movement of Inspection tools / pigs.
2.0 REFERENCE DOCUMENTS:

Reference has also been made in this specification to the latest edition of the following codes, standards and specifications: ASME B 31.8 ASME B16.9 ASTM A370 ASTM E 92 ASTM E 709 ASNT-SNT-TC-1A API 5L MSS-SP-75 ISO 9000 ISO 9001 : : : : : : : : : : Gas Transmission and Distribution Piping System Factory made Wrought Steel Butt Welding Fittings Mechanical testing of steel products Standard test method for Vickers Hardness of metallic materials Standard guide for Magnetic particle examination American society of Non-destructive testing Specification for Line Pipe Specification for High Test Wrought Welding Fittings Quality Management and Quality Assurance Standards Quality Systems Model for quality assurance in design, development, production, installation and servicing Metallic products types of inspection documents

EN 10204

ISO 12094

Welded Steel tubes for pressure purposes ultrasonic testing for the
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STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)

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detection of laminar imperfections in strips / plates used in manufacturing of tubes OISD 141 : Design and Construction requirements for cross country hydrocarbon pipelines

In the event of any conflict of data or requirements in any of the above documents, it is the Suppliers responsibility to resolve these conflicts before proceeding with design, manufacture or purchase. In any case, the most stringent requirement shall prevail. However, client / clients representative interpretation shall be final. In case of conflict, the order of precedence of the documents shall be as follows: 3.0 National and / or local regulations Technical Data Sheets This Specification Project Specifications & Company Standards International Codes as per Paragraph 2.1

MATERIALS & REQUIREMENTS: 3.1 The design code, design factor, rating, corrosion allowance, grade of material, nominal diameter and nominal wall thickness of mating main pipe and branch pipe shall be as stated in the Material requisition. Tees with branches 25% or more than the main pipeline diameter shall have a configuration of bars as indicated in Annexure-A. The bars shall be made of mild steel, ASTM Grade hardness tested applications, and shall be full penetration welded using a qualified procedure. The Tees shall be designed to the design code as stated in the material requisition, and shall be manufactured to MSS SP-75 as appropriate and the requirements of this specification. Full encirclement Tee shall not be allowed. The Tees shall meet or exceed the strength requirements of the matching pipe as calculated by ASME B 31.8. Data supporting the design in form of calculations and drawings shall be submitted for approval prior to commencement of manufacture. Design shall be in strict accordance with the appropriate design code. Documented data of successful proof tests according to the relevant standard shall be submitted in support of the design. The wall thickness of weld ends at the bevel of main run and branches of Tees shall have a bevel thickness no greater than 1.5 times the nominal wall thickness of the mating pipe. A 1:4 taper on the outside diameter at the
STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE) DOCUMENT NO. S-04-02-016 REV-0 Page 4 of 12

3.2

3.3

3.4 3.5

3.6

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ends of the pipe will be acceptable, if the wall thickness of the body of the Tee exceeds this dimension. 3.7 3.8 3.9 3.10 Vendor shall check & confirm the number of bars (as stated in Appendix-A) required for Tees. All pipeline Tees shall be suitable for passage of instrumented inspection tools in either direction. Fully killed carbon steel shall be used. Material of the ends to be field welded by purchaser shall have carbon equivalent less than or equal to 0.45 based on check analysis, for each heat of steel, calculated according to the following formula. Mn Cr + Mo + V -------- + --------------------6 5 Ni + Cu --------------15

CE = 3.11

C+

When specified in data sheet, hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise. When specified in the Data Sheet, charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of 0 C. The charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Average impact energy value of three full sized specimens shall be 27 joules. Minimum impact energy value of any one specimen shall not be less than 80% of the average impact energy specified. No specimen shall exhibit less than 80% shear area. The Tees shall be manufactured from material, which meets the specified minimum yield strength of the mating pipe and shall be as indicated in the data sheet. The material for flow Tee shall consist of blooms, billets, slabs, forging quality bar, plate, seamless or fusion welded tubular products with filler metal added. The material shall be as per MSS SP-75 or suitable API Standard 5L pipe to achieve tensile properties as indicated in the data sheet. The fittings shall be heat treated by normalizing, quenching and tempering to achieve the same strength of line pipe.
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3.12

3.13

3.14

3.15 3.16

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3.17 3.18 3.19

Fittings shall not be machined from bar stock or solid forged billets. Tees shall be supplied in normalized, normalized and tempered or quenched and tempered condition. A ring of material may be required from the main run of pipe for weld procedure qualifications for the main pipeline. Rings shall be 400mm minimum in length and subject to the same forging and heat treatment as the supplied Tee.

4.0

MANUFACTURE QUALIFICATION AND PRODUCTION TESTING: 4.1 MANUFACTURE:

4.1.1 Tees shall be made by forging the branch from a suitable pipe and / or a pre-bent fabrication and shall have a maximum of one seam weld only. Circumferential welds are not permitted. Seamless fittings are preferred. 4.1.2 The chemical and physical properties of the material shall meet the line pipe specifications. 4.1.3 The manufacturer shall submit a manufacturing procedure for approval by purchaser prior to manufacture of Tees. 4.1.4 Double sided submerged Arc welding is required for the longitudinal weld in the main run. Single sided weld requires specific approval from Purchaser. 4.2 QUALIFICATION:

4.2.1 A Tee shall be qualified when it passes all production testing as required by clause 5.3 of this specification. The qualification is valid for the main and branch nominal pipe size combination, per grade, heat treatment and manufacturing route only. However, a Tee with an equal branch will qualify for Tees with the same main OD with smaller branch ODs of the same grade or lower grades. 4.2.2 A test ring from the main run and prolongations of the forged branch of the Tee shall be tested to qualify the manufacturing route per size, grade, and heat treatment and material source. 4.2.3 Welds and body shall be tested in accordance with clause 5.3 of this specification. Testing shall be carried out per steel source per heat. 4.2.4 The full penetration welds for the bars shall be qualified to ASME Sec. IX or other welding code approved by Purchaser. 4.2.5 All welding, including weld repairs, shall be performed in accordance with the procedure approved by Purchaser and welders qualified in accordance
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with ASME Sec. IX and API 1104. Welding procedures required for non-sour service applications shall also include the hardness tests. 4.3 PRODUCTION TESTING: Destructive testing of fittings shall include the tests as given below. Specimens and testing shall be carried out in accordance with clause 6.2 of API 5L and shall meet the acceptance of relevant line pipe specification. Test frequency shall be once per heat, per heat treatment batch, per grade of material for each size of Tee. The minimum test temperature shall be 00C. 4.3.1 One tensile test to include the weld (if present) and one tensile test to include the body of the main run, one tensile test to include the extruded branch. Specimens shall be transverse. The Charpy V-Notch test shall consist of three specimens. Longitudinally welded Tees shall include one set in the body and four sets to be taken from the weld (if present), one set to be taken from each of the weld centerline, fusion line, fusion line + 2mm, fusion line + 5mm. One set shall be taken from the extruded branch. All charpy specimens shall be transverse. Proof tests (Bursting tests) as per MSS SP-75. However, this requirement can be waived by Purchaser, where documentary evidence is provided for the design of Tee proven by previous proof testing, in support of the design by the vendor.

4.3.2

4.3.3

5.0

INSPECTION AND TESTS: 5.1 GENERAL:

5.1.1 All personnel, performing the non-destructive tests (NDT) shall be qualified in the technique applied, in accordance with ASNT-TC-1A Level II by a third party, or equivalent approved by the Purchaser. 5.1.2 Original certificates shall be made available for inspection by purchaser / purchasers representative at the Vendors premises, if required. Personal interpreting results of any NDT shall be qualified by a third party to SNT-TC1A, Level II or III. 5.1.3 All NDT shall be performed in accordance with written procedures. These procedures shall have the prior approval of the Purchaser. 5.1.4 NDT shall be carried out on Tees after all mechanical testing, manufacturing stages and heat treatment have been completed.
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5.2

VISUAL INSPECTION:

5.2.1 100% Visual inspection shall be carried out. The body of every fitting shall be inspected internally and externally for surface defects. 5.2.2 The surfaces of the fitting shall be free from all dents, gouges, laps, score marks, arc strikes, under cuts or other detrimental defects. 5.2.3 Welds shall be inspected visually for 100% of the length, both outside and inside. The requirement of workmanship shall be as per the connected line pipe. 5.2.4 Defects shall be removed by grinding or by weld repair except that welding is not allowed on the body of the Tee. Weld repairs shall be qualified and carried out in accordance with the applicable line pipe specification. 5.3 NON-DESTRUCTIVE TESTING OF FITTING:

5.3.1 100% Radiographic testing of all seam welding shall be carried out in accordance with ASME Sec VIII, Div 1, Clause UW 51. For Butt welds in Tees, with a thickness greater than 20mm (0.8 inches) , radiographic inspection may be replaced with Ultrasonic inspection at the discretion of Vendor. 5.3.2 For the acceptance of radiographic films, the technique used shall result in sensitivity better than 2% of thickness of the weld metal and a relative film density of 2 to 3.5 in the weld metal. 5.3.3 The manufacturer shall record on review form accompanying the radiograph, the interpretations of each radiograph and disposition of the fitting inspected. 5.3.4 The penatrameter used shall be of the wire type in accordance with ISO 1027. The selection of penatrameter wire diameters shall be based on a sensitivity of 2% of weld metal thickness. Penatrameter must be placed source side. 5.3.5 Magnetic particle inspection (MPI) of 100% surface of the Tees, all bevel ends and all welds shall be in accordance with the requirements of ASTM E709. The wet method shall be used, use of probes is unacceptable. Relevant linear indications greater than 3mm in bevel ends shall require rebeveling. Any ground surface shall be re-inspected by MPI to verify that the indication has been removed. The beveled surface shall be free from defects such as cracks, laps or laminations visible to the naked eye as revealed by MPI. 5.3.6 Ultrasonic tests (UT) shall be carried out on all bevel ends of all fittings, in accordance with ASTM E709. Relevant linear defects greater than 3mm are
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non-acceptable. Longitudinal edges and body of plate for seam welded fittings shall be tested in accordance with applicable specification of line pipe. UT shall be as per applicable line pipe specifications. 5.3.7 All repairs shall include a minimum preheat of 1000C, unless the qualification test shows that a higher temperature is necessary. 5.3.8 Each repair welding procedure shall be qualified on a pipe section under realistic conditions in accordance with API 5L Appendix-C and this specification. 5.4 DIMENSIONAL INSPECTION:

5.4.1 Each Tee shall confirm to the dimensional requirements of ASME B 16.9 or MSS SP-75 as appropriate and the additional requirements of this section. 5.4.2 The ends of each fitting shall be tested for out of roundness using an internal ring gauge with a diameter of 5mm (0.2 inch) less than the nominal internal diameter. The gauge shall pass freely into each end of the fitting for a distance of 100mm when held perpendicular to the fitting axis. 5.4.3 The tolerance for the internal diameter of the run pipe part of the Tee shall be within 0 to +1.5mm (0 to 0.059 inches) of the nominal dimension of the connecting pipe at the ends. 5.4.4 End bevel preparation for the Tees shall be in accordance with API 5L. If necessary, the ends shall be machined such that the maximum wall thickness at the ends of the Tee is no greater than 1.5 times the nominal wall thickness of the mating pipe. A taper of 1:4 is permitted on out side only to reduce the thickness of the Tee body to meet the thickness of the weld bevel. 5.4.5 A gauging Pig shall be passed through the main run of each Tee. The pig shall consist of two aluminum plates of at least 3mm thick, joined by a rigid rod through their centers. The diameter of the plates shall be 95% (tolerance 0 to +1mm) of the nominal inside diameter of the main pipe. The Pig shall pass without sticking or damage to the Tee. 5.4.6 The gap produced when a flat plate perpendicular to the Pipe Axis is held against the machined bevel of main and branch pipe ends shall be within +3.0mm. 6.0 COATING / PAINTING: After sand blasting and cleaning the surface (SA 2 ) of the Barred Tee, the following coating shall be applied. For under ground Barred Tees:
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Coal Tar Polyurethane or equivalent, which shall be approved by Purchaser. The DFT shall be 875 microns.

For above ground Barred Tees: 7.0 Zinc rich epoxy primer. The DFT shall be 50 microns.

MATERIAL CERTIFICATION AND TRACEABILITY: 7.1 Material test certificates and manufacturer test reports shall be traceable to each Tee within the Vendor Fabrication Book, which shall be part of the QC Data bank. The pressure containing and load bearing / stressed materials shall be fully covered by the material test certificates which shall bear Equipment tag numbers, Purchase order numbers and any other Purchase order requirements.

7.2

8.0

PREPARATION FOR SHIPMENT: The vendor shall submit shipping and handling procedures to Purchaser for approval. The procedures should adequately address storage, shipping and handling in view of the long voyage from manufacturing locations and climatic extremes at the job site. An appropriate design of end cap shall be fitted to each opening to protect the butt weld ends and prevent ingress of foreign material.

9.0

MARKING: The vendor shall mark each fitting with the information specified below as a minimum. The markings shall be painted on the outside surface and shall be executed white block capitals of minimum height inch. Project Name Manufacturers name and unique identification number of the fitting Nominal header pipe diameter (inches) and wall thickness (mm) Nominal branch pipe diameter (inches) and wall thickness (mm) Material Grade Design Pressure and test Pressure (when applicable) Purchase Order and Item Number Cast number

10.0 VENDOR DATA REQUIREMENTS: During the fabrication, the Vendor shall submit certification and inspection documents to the Purchaser as specified in the Purchase order. Documents shall include the following as minimum. Quality Plan
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Manufacturing Procedures covering steel making, chemical composition, welding and forming procedure. Certified material test reports, 3.1B to EN 10204, for all sizes. NDT test reports and operator qualifications All mechanical test reports Certificate of conformance and dimensional check reports Heat treatment procedure reports All concession requests Design Burst test information

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STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)

DOCUMENT NO. S-04-02-016

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STANDARD SPECIFICATION FOR FLOW TEE (BARRED TEE)

DOCUMENT NO. S-04-02-016

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STANDARD SPECIFICATION FOR SCRAPER TRAPS

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STANDARD SPECIFICATION FOR SCRAPER TRAPS

DOCUMENT NO. S-04-02-017

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CONTENTS
Sl. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Description SCOPE REFERENCE DOCUMENTS MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT GUARANTEE SPARES DOCUMENTATION

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SCRAPER TRAPS

DOCUMENT NO. S-04-02-017

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1.0

SCOPE:

This specification covers the basic requirements for design, manufacture, inspection, testing & supply of scraper launching & receiving traps to be installed in pipeline system transporting Natural Gas.
2.0 REFERENCE DOCUMENTS:

2.1

Reference has also been made in this specification to the latest edition of the following codes, standards and specifications: ASME B 31.1 ASME B 31.3 ASME B 31.8 ASME B 16.5 ASME B16.9 ASME B 16.11 ASME B 16.25 ASTM A 105 ASTM A 181 ASTM A 216 : : : : : : : : : : Power Piping Process Piping Gas Transmission and Distribution Piping System Steel Pipe Flanges and Flanges Fittings Factory made Wrought Steel Butt Welding Fittings Forged Steel Fittings, Socket-Welding and threaded Butt-Welding Ends Forging, Carbon Steel for Piping components Forging, Carbon Steel for general purpose piping Carbon Steel Castings suitable for Fusion Welding for High temperature Service Piping Fitting of Wrought Carbon Steel and Alloy Steel for moderated and Elevated Temperatures Mechanical testing of steel products General requirements for steel plate for pressure vessels Carbon steel pressure vessel plates for moderate and low temperature service
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ASTM A 234

ASTM A370 ASTM A 20 ASTM A 516

: : :

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR SCRAPER TRAPS

Copyright GAIL All rights reserved

ASTM A 106 ASTM A 193 ASTM A 194 ASME Sec-V, VIII and IX API 1104 API 5L MSS-SP-6

: : : : : : :

Carbon steel seamless pipe for high temperature service Alloy steel and stainless steel bolting materials for high temperature Carbon and alloy steel nuts for bolts for high pressure or temperature Boiler and Pressure Vessels Codes Specification for Welding Pipeline and Related Facilities Specification for Line Pipe Standard Finishes for Contact Faces of Pipe Flanges and Connecting End Flanges of Valves and Fittings Specification for High Test Wrought Welding Fittings Specification for High Test Wrought Welding Fittings Integrally Reinforced Forged Branch Outlet Fittings Socket Welding Threaded and Butt Welding Ends Steel Structure Painting Council Steel and Steel Structures Inspection documents Quality Management and Quality Assurance Standards Quality Systems Model for quality assurance in design, development, production, installation and servicing Quality Systems Model for quality assurance in production, installation and servicing

MSS-SP-44 MSS-SP-75 MSS-SP-97

: : :

SSPC-VIS-1 ISO 10474 ISO 9000 ISO 9001 ISO 9002

: : : : :

In the event of any conflict of data or requirements in any of the above documents, it is the Suppliers responsibility to resolve these conflicts before proceeding with design, manufacture or purchase. In any case, the most stringent
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requirement shall prevail. However, client / clients representative interpretation shall be final. In case of conflict, the order of precedence of the documents shall be as follows: 3.0 Technical Data Sheets This Specification Project Specifications, Company Standards and International Codes as per Paragraph 2.1

MATERIALS: 3.1 Materials and thicknesses of main components used in manufacture of traps shall be indicated by Manufacturer and shall be suitable for service conditions indicated in the data sheets / Technical specifications. These shall be subject to approval by purchaser. The steel used shall have a minimum SMYS of 35,000 psi. Fully killed carbon steel shall be used. Material of the ends to be field welded by purchaser shall have carbon equivalent less than or equal to 0.45 based on check analysis, for each heat of steel, calculated according to the following formula. Mn Cr + Mo + V -------- + --------------------6 5 Ni + Cu --------------15

3.2 3.3

CE = 3.4

C+

For Materials of Barrel, Neck, Charpy V-notch test shall be conducted at -20C and 00C. The minimum transverse impact energy values of three full sized specimens (10mm x 10mm as per ASTM E23) shall be as under:
MATERIAL BASE METAL AND WELD TEST TEMPERATURE (-) 200C 00 C MINIMUM AVERAGE VALUE (FOR SPECIMENS) 35 J 100 J MINIMUM SINGLE VALUE 27 J 75 J

Impact test shall be carried out on samples with the notch at the following locations for the weld zone: Weld Metal Fusion line Fusion line + 2mm Fusion line + 5mm

The four sample locations specified above shall constitute of 3 test specimens each, and shall be taken from the mid-thickness of the weld.
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Impact test shall also be carried out on a transverse sample (3 test specimens) removed from the base metal. The samples shall beat 90 shore D to weld scam. Shear area at the fracture surface shall be recorded. The shear area shall be determined for base metal samples only. The required levels are 85% average fibrous shear, and 75% individual minimum. The test specimens shall be in a transverse direction with the notch axis oriented through the pipe wall /plate wall thickness. All carbon steel forgings shall be heat-treated either in the normalized, normalized and tempered or quenched and tempered condition. 3.5 For Scraper Traps, hardness test shall be carried out as per ASTM A370 for each heat of steel used. A full thickness cross section shall be taken for this purpose and the maximum hardness of the base material, weld metal and heat affected zone (HAZ) of all the pressure containing parts shall not exceed 248 HV10. The maximum difference in hardness of Base metal, Weld metal and Heat affected zone (HAZ) of pressure containing parts of the traps shall be less than 80 points Vickers HV10. Material Test Certificates provided by the MANUFACTURER shall conform to ISO 10474 for the following:
COMPONENTS All pressure retaining parts (for minor and major barrel, reducer and quick opening closure) All parts in contact with fluid (for nozzles and flanges) All attachments welded to the vessel Trap assembly inspection and test Vessel structural supports and non pressure parts Others, if any MATERIAL CERTIFICATION REQUIRED EN10204Type 3.2C EN10204Type 3.2 C EN10204Type 3.2C EN10204Type 3.2C EN10204Type 3.2C EN10204Type 3.2C

3.6

Certified mill test report, showing the chemical and physical properties for each item of material furnished by the Manufacturer, shall be witnessed / reviewed by third party Inspection agency (TPIA). A report of results obtained from magnetic particle and radiographic examinations of welds indicating all defects were identified and the disposition of all repairs shall be provided. All original radiographs shall be available to the PURCHASER / PURCHASERS REPRESENTATIVE/TPIA for review upon request. A list of welders shall be provided on the drawings to indicate who made each weld.
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A certified copy of all hydrostatic test charts shall be provided. Owners approved Third Party Inspection Agency (TPIA) shall be deputed by the MANUFACTURER for inspection at manufacturer premises to witness / review material Tests certification as per EN-10204 type 3.2C certification at manufacturers cost. 4.0 DESIGN, CONSTRUCTION & FABRICATION: 4.1 DESIGN & CONSTRUCTION:

4.1.1 The cylindrical portion of the trap shall be designed as per design code and design factor indicated in the data sheets. Quick end closure shall be designed as per sec. ASME Sec. VIII, Div. 1 for design conditions indicated in data sheets. A corrosion allowance of 3mm shall be considered in design of the traps. Quality of welding shall be such that weld efficiency factor of 1.0 is achieved. 4.1.2 The trap shall be capable of handling instrumented pigs, model like Linalog 360 of AMF Tuboscope or British gas magnetic inspection vehicle or equivalent and scraper pigs as specified in scraper Trap data sheet. 4.1.3 The trap body and neck, diameter has been indicated in the data sheet. Trap length to suit the purpose and thickness to meet the class rating shall be suggested by the manufacturer and approved by the purchaser. Circumferential weld on scraper trap body and neck shall not be permitted. 4.1.4 Concentric or eccentric reducer, as indicated in data sheets, used in the manufacture of traps shall conform to MSS-SP-75 (as per the grades specified in the data sheets). Thickness of the Reducer shall match with that of the adjoining body / neck thickness. 4.1.5 Vents and drains shall be provided on each trap. The trap shall be provided with a suitable slope and the drain location shall be such that complete drainage of the trap is possible. Sizes for vent and drain shall be as indicated in data sheet. In case of Scraper Receiver, the minimum slope shall be 1:100 downwards the end closure where as in case of Launcher it shall be 1:100 downwards the pipe line. 4.1.6 All branch connections shall be made by weldolets/ nippolets or by extrusions as indicated in the data sheet. All weldolets shall confirm to MSSSP-97 and nippolets shall be of manufacturers standard. The extruded opening shall be adequately heat treated and stress relieved. 4.1.7 End connections of traps shall be flanged or butt welded as indicated in data sheet. a) Flanged ends, if specified shall have dimension as per ASME B16.5 for sizes up to 24" NB (excluding 22 NB) and as per ASME B16.47 / MSSGAIL (INDIA) LTD NEW DELHI STANDARD SPECIFICATION FOR SCRAPER TRAPS DOCUMENT NO. S-04-02-017 REV-0 Page 7 of 17

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SP-44 for sizes 22 NB and 26 NB and above. Flanges shall be as indicated in data sheets. b) Butt weld ends if specified shall have ends prepared as per ASME B16.25. However, end preparation for butt welding ends having unequal thicknesses with respect to connecting pipe shall be as per ASME B31.4/ ASME B31.8 as applicable. The location & orientation of all nozzle connections shall be submitted for purchaser's approval before manufacturing.

c)

4.1.8 The quick opening end closure shall be of quick actuating GD band lock type or equivalent design. The design of the quick opening end closure shall be in accordance with design code adopted for the adjoining pig trap as stated in the data sheet. The design of the end closure shall be robust and should consider fail safe design of the opening mechanism and allow opening and closing by one man in a period of approximately one minute without the use of additional devices. The closure shall also consist of a safety relief system allowing the opening only when there is no pressure in the trap. Safety bleeder device shall alert operator of possible hazard unless pressure in the pig trap is relieved completed. Screwed type or plug-in types of end closures are not acceptable. End closures of size 24" and above shall be fitted with worm gear operator for the opening of the closure. Hinge of the closure shall be so designed that the weight of the end closure is fully supported with out sagging. The end closure shall be designed in accordance with safety requirement of ASME Sec. VIII Div. 1, Clause UG-35. End closure hinge axis shall be horizontally aligned, not withstanding any slope on the barrel section. 4.1.9 Traps shall be provided with a pig indicator in the middle of the neck and the indicator shall conform to the specification issued for the purpose. Pig indicator shall be suitable for bi-directional operation and shall have visual flag and manual reset. The same shall also have provision for remote indication. Refer Pig Signaler Data Sheet. 4.1.10 The Scraper trap shall be supplied with Pig Handling system, Jib Crane and Winch for pulling the SS tray and Pig as mentioned below. Pig handling trolley shall be designed from structural steel and shall be suitable to move on rail through a gear train. Trolley shall be designed to contain pig tray which will contain pig. Trolley shall have proper braking system. Pig tray shall have perforated holes and shall be suitable to contain any type of pig, including intelligent pig.
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Tray shall have proper strengthening system to avoid bending with load. The tray shall be provided with suitable stops. Lock bracket shall be provided such that the tray does not stop within the Launcher / Receiver. Rear end of the tray shall be provided with suitable lug to enable retrieval of the tray by hooks. The handling system (for inserting and retracting the intelligent pigs from the equipment) shall be complete with handling devices. In case any rails are required for sliding of the handling system, the same shall be provided by the Scraper Launcher / Receiver manufacturer. Winch to push tray and pig inside the launcher / receiver shall be provided. Complete system shall be designed to operate by one person. Jib Crane shall be designed as per IS: 3177, IS: 3832, IS: 3938 of latest edition and shall be mounted on a structural column. Jib Crane shall swivel 3600 with one person and shall have antifriction bearing for swivel operation. Lifting of equipment and movement of Trolley shall be anti-spark type HoistTrolley system, suitable to operate by one person. Crane shall be balanced with load at maximum span and shall have counter weight if required. Suitable locking and braking system shall be provided. End stoppers shall be provided for trolley movement. Crane shall be tested with 1.5 times of rated load at maximum radius. Deflection test shall be as per IS: 807 of latest edition. Wire ropes used for hoisting and traveling shall be checked as per IS: 6594 and IS: 3973 latest edition. Crane shall be complete with foundation bolts. Jib crane shall be designed to be operated by one man for all operations. Manufacturer shall furnish all technical parameters of Pig handling system, Winch and Jib Crane along with offer.

4.1.11 Fabricated steel supports, minimum two numbers at suitable spacing shall be provided with traps for mounting on concrete blocks. These supports will not be subjected to pipeline anchorage forces. The material of support shall be compatible with trap material for welding purposes. All welds shall be examined by magnetic particle method. 4.1.12 Completed assembly shall be stress relieved as per the provisions of the design codes.
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4.1.13 Welds shall be made by welders and welding procedures qualified in accordance with the provisions of ASME Sec. IX. The procedure qualification shall include impact test and hardness test when required as per clause 3.4 & 3.5 of this specification and shall meet the requirements as specified therein. 4.1.14 Repair by welding on parent metal is not allowed. Repair of welds shall be carried out only after specific approval by purchaser's representative for each repair. The repair welding shall be carried out by the welders and welding procedures duly qualified as per ASME Section IX and records for each repair shall be maintained. The repair welding procedure qualification shall include impact test and hardness test when required as per clause 3.4 & 3.5 of this specification and shall meet the requirements as specified therein. 4.1.15 The traps shall be equipped with a half internal removable filtering basket consisting of a punched plate with a least five rows of drain holes. 4.1.16 The filtering basket shall slide on guides on wheels and in all cases the material of the parts being in contact with each other shall be of the anti spark type. 4.1.17 The tolerance on internal diameter and out of roundness at the ends for the welding end of the neck (at the end where connecting pipeline will be welded) shall be as per applicable connected pipe specification as indicated in the data sheet. 4.1.17 Opening for nozzles shall be from material conforming to the same requirements as the pressure containing parts, and adequately reinforced as per ASME B31.8. All nozzles shall be flushed with the inside contour of the barrel. The minimum distance between the edge of any attachment weld of a pressure part (e.g. a nozzle) to the edge of another pressure weld of the trap body shall be 50 mm or twice the thickness of the pressure part, whichever is the greater. The nozzles shall be terminated with weld neck type raised faced flanges conforming to ASME B16.5/16.47. 4.2 FABRICATION:

4.2.1 General: Prior to commencement of fabrication, calculations and fabrication drawings, welding procedures (WPSs, PQRs and supporting lab test reports), procedures for NDT, PWHT, hydrostatic test, coating, production weld
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hardness testing, and quality assurance plan (QAP) shall be submitted to purchaser / purchasers representative review and approval. The inside of the trap barrel shall be free from obstructions which could prevent the free rolling of spheres, or travel of pigs or carriers. All inside welds shall be ground smooth and nozzle ends shall be made to suit inside curvature of barrel. The inside diameter of the minor barrel of the trap and the main flange shall match the inside diameter of the pipeline on which it is to be installed. Gasket contact surface of flanges shall be protected against oxidation during the PWHT. 4.2.2 Welding: Welding shall be performed with procedures and operators who have been qualified in accordance with the design code and ASME code Section IX. All welding procedures, qualification of welders and welding procedure qualifications, design and preparation of joints, inspection and testing, standards of acceptability of welding, repairs and radiography shall be fully in accordance with design code and shall be documented by MANUFACTURER before fabrication commences. No welding shall be carried out after post weld heat treatment. The final non-destructive testing of welds for acceptance purposes shall be carried out after completion of any post weld heat treatment (PWHT). Tack welds for welding fit-up shall be removed when making the final welds. All welds shall be continuous unless specified otherwise. All main seam welds and nozzle to shell welds shall be of full penetration type. Double side welding shall be carried out wherever possible. Single welded butt joints are permitted for circumferential joints and will be 100% radiographically tested. All weld spatters and arc strikes shall be removed by grinding prior to inspection and testing of welded joints. All repair works on pressure parts welding shall be in accordance with approved weld repair procedure. No attachments weld shall intersect any seam weld or lie in 50 mm or less than 2 times the thickness of shell whichever is greater (if this is not applicable, MANUFACTURER shall provide he practicable limits and perform the necessary NDT / calculation). Corners of reinforcement pad shall be radiuses.
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4.2.3 Tolerance: Diameter and out of roundness tolerances for the minor barrel shall be in accordance with the requirements of Project Specification for Line Pipe. The maximum straightness deviation, measured at the outside surface of the cylinder from a straight line parallel to the vessel axis, shall not exceed 1.5mm per 1000 mm cylindrical shell length. Tolerance on overall length shall be to + 10 mm with respect to approved drawings. Nozzles tolerances with respect to approved drawings shall be in accordance with the following requirements: Position Projection Alignment of nozzle flange face Radial Bolt hole : Measure from neck end +6 mm : Measure from shell outer surface +3mm : Max. deg in any direction from true vessel axis and true radial centre line : Measured from reference centre line to centre line of nozzle + 2mm : Maximum total indicated run-out 0.2mm from true position.

Alignment of end closure flange face shall be max +1 deg in any direction. 5.0 INSPECTION AND TESTS: 5.1 The manufacturer shall perform all inspections and test as per the requirements of this specification and the relevant codes prior to shipment at his works. Such inspections and tests shall be, but not limited to, the following:5.1.1 All traps shall be visually inspected. Undercuts, overlaps, craters and other unacceptable defects on the welds shall be removed and / or welded. 5.1.2 Chemical composition and mechanical properties including hardness shall be checked for each heat of steel used. 5.1.3 Dimensional check shall be carried out as per the approved drawings. 5.1.4 If the traps are provided with welded reinforced attachments, tell-tale holes shall be provided in order to test with dry air at 7 bar g pressures and checked with foam agent for leaks. This shall be carried out prior to the final hydrostatic pressure test. 5.1.5 Hydrostatic test shall be conducted for all scraper traps complete in all respects including mounting of pig indicators at a pressure equal
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to 1.5 times the design pressure. The test pressure shall be held for a minimum period of four hours. The temperature of the trap material and test liquid shall not be less than 10C during the hydrostatic test. A continuous recording of the pressure test is to be made including a calibration (witnessed and certified) and is to be included in the documentation to be provided by MANUFACTURER. The pressure test shall be performed after completion of all welding, heat treatment, installation of any specified instrument and building of all flanges, and before painting. Quick opening type end closure shall be hydro-tested for minimum 24 hours in 20 cycles from zero to hydrostatic test value. 5.1.6 A minimum of two closing and opening cycles shall be performed and correct operation of both quick opening closure and safety system shall be ascertained after the pressure cycles. No excessive force should be required to operate the mechanism. 5.1.7 Non-destructive examination shall be carried out as per code but shall not be less than the following: QOC forgings and mainline flange : UT All pressure part butt joints Nozzle to shell joint : : 100% RT and UT 100% UT and MPT 100% MPT and PT 100% MPT or PT 100% Ultrasonic 100% RT scan

Attachments welds and lifting lug welds : All mating clamp and machined surfaces, Door hinges attachment of end closure : Pig Trap barrel / Body material Seam : :

Ultrasonic inspection is required on Pig trap shell material where locally reinforced fittings are to be welded. Prior to welding all weld ends are also to be checked using ultrasonic inspection. NDT examination and acceptance criteria shall be as follws:
NDT METHOD Ultrasonic Testing for Forgings Ultrasonic Testing for GAIL (INDIA) LTD NEW DELHI PROCEDURE ASME Sect. V. Article 5 & 23 ASME Sect. V. Article 5 & 23 ACCEPTANCE CRITERIA ASME Sect. VIII, Div. 3, Art. AM 203.2(c) ASTM A 578, Level I Cracks DOCUMENT NO. S-04-02-017 REV-0 Page 13 of 17

STANDARD SPECIFICATION FOR SCRAPER TRAPS

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Shell & Welding Ends Ultrasonic Testing for welds Magnetic Particle Dye Penetrant Radiography

ASME Sect. V. Article 5 & 23 ASME Sect. V. Article 5 & 23 ASME Sect. V. Article 5 & 23 ASME Sect. V. Article 5 & 23

Not Allowed ASME Sect. VIII, Div. 1, App. 12 ASME Sect. VIII, Div. 1, App. 6 ASME Sect. VIII, Div. 1, App. 6 ASME Sect. VIIII, Div. 1, Art. UW51

5.2

Purchaser's Representative reserves the right to perform stage wise inspection and witness tests including hydrostatic test, as indicated in specification at manufacturers works prior to shipment. Manufacturer shall give reasonable notice of time & shall provide without charge reasonable access and facilities required for inspection, to the purchaser's representative. Inspection and tests performed / witnessed by Purchaser's Representative shall in no way relieve the Manufacturer's obligation of specific integrity of the scraper traps. Manufacturer's equipment shall be subject to examination and approval by purchaser to ensure proper fabrication and testing of traps.

6.0

TEST CERTIFICATES: Manufacturer shall furnish the following certificates: a) Test certificates relevant to the chemical and Mechanical properties including Hardness of the materials used for manufacture of trap as per relevant standards and this specification. Hydrostatic test certificates. Test reports on radiography, ultrasonic inspection and magnetic particle examination. Test reports on heat treatment carried out, if any.

b) c) d)

The certificate shall be considered valid only when signed by purchasers representative. 7.0 PAINTING, MARKING AND SHIPMENT: 7.1 After all inspection and tests required have been carried out; all external surfaces shall be thoroughly cleaned to remove grease, dust and rust. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with "Steel Structures Painting Council Visual Standard - SSPCVIS-1". Machined parts shall be coated with anti-rust removable paint and non machined parts shall be applied with two coats of protective paint. Manufactures shall indicate the type of paint used in the drawings submitted for approval.
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STANDARD SPECIFICATION FOR SCRAPER TRAPS

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The inner surfaces must be free of loose particles, lamination flakes, welding spatter and sharp edges or any protruding element that interferes with the pig / scraper. 7.2 Marking shall be done on a stainless steel plate and affixed to the body by means of corrosion resistant fasteners. Marking shall include the following:a) b) c) d) e) f) g) h) i) j) k) 7.3 Manufacturer's Name Trap/ Neck Diameter, Thickness Material ASME Class Rating Tag Number Design Pressure Design Temperature Test Pressure Design Factor Year of Manufacture Empty weight of the trap assembly.

Equipment shall be drained of test liquid, cleaned and thoroughly dried prior to shipment. Surfaces subject to atmospheric corrosion or rusting shall be coated with rust preventive. External non-painted surfaces including bolting and flange faces also shall be coated with rust preventive designed for at least six months of storage. All components shall securely anchor to the skid and package supports. All opening, flange facings, etc., shall be sealed with waterproof coverings for shipping. Threaded coupling shall be provided with steel plugs. Two extra O-rings and the closure actuation tool shall be attached to the inside of the barrel to prevent loss. The scraper barrels shall be handled in such a manner to prevent damage, including damage to the bevel or closure. Service bolting and gaskets shall be suitably rated and properly marked. Flanged openings shall be protected with one-piece plywood cover and rubber gasket. Plywood covers shall be 3/8 inch thick, for flanges 6 inches and smaller, inch thick for 8 inch through 12 inch flanges, and inch thick for larger sizes. A minimum of four 3/8 inch bolts shall be used for flanges 12 inches and smaller end eight 3/8 inch bolts for larger flanges. Large washers shall be used on the flange side of the bolt. Suitable washers shall be used on the plywood side of all such covers. Only those traps, which have been inspected and certified by the purchasers inspector shall be supplied.
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7.4 7.5 7.6

7.7

7.8 7.9 7.10

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8.0

GUARANTEE: 8.1 Manufacturer shall guarantee that the trap along with accessories is in compliance with the requirements of this specification for materials and workmanship. Manufacturer shall replace or repair all parts which should result defective due to inadequate design or the workmanship. In case the defect can not be eliminated, Manufacturer shall replace the trap without any delay. Any defect occurring within the time period specified elsewhere Shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser.

9.0

SPARES: 9.1 Manufacturer shall furnish list of recommended spares and accessories for Scraper Traps required during start up and commissioning. As a minimum, the commissioning spares shall include 200% extra consumable spares viz. gaskets/ o-rings/ seals etc. for each trap. Cost of such spares shall be included by the Manufacturer in the item rates indicated in Purchase Requisition. Manufacturer shall furnish separately a list of recommended spares and accessories required for two years of normal operation and maintenance of Scraper Traps.

9.2

10.0 DOCUMENTATION: 10.1 (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Manufacturer shall furnish the following documents at the time of bidding:Outline General Arrangement Drawings of the equipment Completed data Sheets Confirmation of scope of supply, including detailed material and painting specifications Thickness of major and minor barrel Vessel weight data, Erection weight, Operational weight, Maximum weight Materials of Construction Proposed manufacturing/delivery schedule Proposed Quality Assurance/Safety Plan Proposed Surface Treatment Typical Inspection and Test Plan
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(k) (l) (m)

Table of Compliance Catalogue of End Closure Reference list of similar supplies for the past seven years including project, client year of supply & contact person. Failure to provide this information may exclude the manufacturers bid from Evaluation.

10.2

Within three weeks of placement of order, the manufacturer shall submit four copies of, but not limited to, the following drawings, documents and specifications for approval. a) b) c) d) Design calculations according to the relevant codes for the body including branch connections and quick end closures Support Assembly Drawing Trap assembly, Closure assembly and sectional drawings showing all parts with materials and dimensions Welding procedure and method of manufacture

Once the above said documents have been approved by the Purchaser, any changes in design, material and method of manufacturer shall be notified to the Purchaser, whose approval in writing of all changes shall be obtained before the traps are manufactured. 10.3 Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies of all approved drawings, documents and specification as listed in clause 10.2 of this specification. Prior to shipment, the manufacturer shall submit one reproducible and six copies of the following: a) b) 10.5 Test certificate as listed in clause 6.0 of this specification. Manual for installation, erection instructions, maintenance and operations instruction.

10.4

All documents shall be in English Language.

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STANDARD SPECIFICATION FOR SCRAPER TRAPS

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STANDARD SPECIFICATION FOR PIG SIGNALERS

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STANDARD SPECIFICATION FOR PIG SIGNALERS

DOCUMENT NO. S-04-02-018

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CONTENTS
Sl.No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 Description SCOPE MATERIALS DESIGN AND CONSTRUCTION REQUIREMENTS INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT GUARANTEE SPARES AND ACCESSORIES DOCUMENTATION

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STANDARD SPECIFICATION FOR PIG SIGNALERS

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1.0

SCOPE:

This specification covers the basic requirements for design, manufacture, inspection, testing & supply of Pig Signalers used for detection of the passage of scraper and instrumented gauging pigs to be installed in pipeline system transporting Natural Gas. 2.0 MATERIALS: 2.1 All materials used in the manufacture of the main components of the pig signallers shall be as indicated in the data sheets. Other components shall be as per manufacturer's standard suitable for the service conditions indicated in Annexure I and data sheets which will be subject to approval by Purchaser. Fully killed carbon steel shall be used. Material of the ends to be field welded by purchaser shall have carbon equivalent less than or equal to 0.45 based on check analysis, for each heat of steel, calculated according to the following formula. Mn Cr + Mo + V -------- + --------------------6 5 Ni + Cu --------------15

2.2 2.3

CE = 2.4

C+

The maximum hardness of Base metal, Weld metal and Heat affected zone (HAZ) of pressure containing parts of the traps shall be 248 points Vickers HV10.

3.0

DESIGN AND CONSTRUCTION: 3.1 3.2 Pig signallers shall be bi-directional type having pivot-less tumbler mechanism and laminated trigger blades. Pig signallers shall be designed to meet the requirements of pipeline material, diameter, wall thickness & service conditions indicated in the data sheet. Design of pig signallers shall be such that any possibility of signaler being operated by line pressure is eliminated. Design of pig signallers shall also be such that repair and installation of internals/ accessories are possible under pressure, without removing the unit from the line.

3.3 3.4

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3.5

Pig signallers shall be provided with a visual indicator to indicate the passage of pigs, by means of spring loaded metal shaft. The arm shall lock in down position when manually reset. Pig signalers shall be fitted with sealed, weather proof and explosion proof micro switch for remote signal indication. The area classification and rating of micro switch shall be as indicated in data sheet. Suitable for installation in NEC class I Division 1, hazardous area. Micro switch shall have the following rating: 2 Amp, 24 Volts, 50 Hz. Type : SPDT. Contacts : 2 NO and 2 NC

3.6

3.7

All welds shall be made by welders and welding procedures qualified in accordance with the provision of ASME Section IX. The procedure qualification shall include hardness test and shall meet the requirements of clause 2.4 of this specification Whenever specified in the data sheet, pig signallers shall be provided with extension, suitable for installation on underground pipeline.

3.8

4.0

INSPECTION AND TESTS: 4.1 4.2 4.3 4.4 4.5 Manufacturer shall perform all inspection and tests required to supply the signallers as per the requirements of this specification. All pig signallers shall be visually inspected. Chemical composition & mechanical properties including hardness shall be checked for each heat of steel used. All welds shall be non-destructively examined. The welding end shall be inspected ultrasonically over the entire circumference for lamination type defects. Any lamination larger than 6.35mm shall not be acceptable. Hydrostatic test shall be conducted at a pressure equal to 1.5 times the design pressure. Hydro test duration shall be 15 Minutes. Manufacturers shall perform functional tests to establish satisfactory performance of both manual and electrical indications.

4.6 4.7

5.0

TEST CERTIFICATES:

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STANDARD SPECIFICATION FOR PIG SIGNALERS

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5.1 5.2 5.3 6.0

Manufacturer shall supply the test certificates for material compliance as per the relevant Material Standards. Certificate for hydrostatic test and functional test. Test reports on heat treatment carried out, if any.

PAINTING, MARKING AND SHIPMENT: 6.1 Exterior surface of the pig signallers shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Manufacturer shall indicate the type and corrosion resistant paint used in the drawings submitted for approval. In case of pig signallers with extension, the buried portion shall be coated with three coats of coal tar epoxy resin. The minimum dry film thickness shall be 300 microns. A corrosion resistant metal tag shall be permanently attached with each unit, with the following marking:i) ii) iii) iv) 6.3 Manufacturers name Suitable for installation in_______mm dia. pipeline ANSI Rating Tag No.

6.2

Each unit shall be suitably protected to avoid any damage during transit. Care shall be exercised during packing to prevent any damage to the welding ends. All machined surfaces subject to corrosion shall be well protected by a coat of grease or other suitable materials.

7.0

GUARANTEE: 7.1 Manufacturer shall guarantee that the pig signallers comply with the requirements stated in this specification and in the purchase order. Manufacturer shall replace or repair all parts found to be defective due to inadequate engineering or quality of material. Manufacturer shall replace the signaler without delay, if the defect or malfunctioning cannot be eliminated. Any defects occurring within the time period specified elsewhere shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser.

7.2

8.0

SPARES: 8.1 Manufacturer shall furnish list of recommended spares and accessories for Pig Signalers required during start up and commissioning. Cost of such spares shall be included by the Manufacturer in the item rates indicated in Purchase Requisition.
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STANDARD SPECIFICATION FOR PIG SIGNALERS

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8.2

Manufacturer shall furnish separately a list of recommended spares and accessories required for two years of normal operation and maintenance of Pig Signallers.

9.0

DOCUMENTATION: 9.1 At the time of bidding, bidder shall submit the following documents:a) b) c) General Arrangement drawing with overall dimensions. Clause wise list of deviation from this specification, if any. Reference list of similar supplies of pig signaler shall be furnished including project, year of supply, client, size, rating and service for last five years.

9.2

Within three weeks of placement of order, the manufacturer shall submit four copies, but not limited to, of the following drawings, documents and specifications for approval. a) b) c) d) Fabrication drawings/ sectional arrangement drawings showing all parts with reference numbers and material specification. Assembly drawing with overall dimension. Welding and testing procedure. Cable connection details and cable specification.

Once the approval has been given by Purchaser, any change in design, material, etc. shall be notified to the Purchaser whose approval in writing for all changes shall be obtained before Pig Signallers are manufactured. 9.3 Within four weeks from the approval date, Manufacturer shall submit one reproducible and six copies of the approved drawings and specifications as listed in 9.2 of this specification. Prior to shipment, Manufacturer shall submit one reproducible and six copies of following: a) b) 9.5 Test certificates as per clause 5.0 of this specification. Manual for installation, erection instructions, maintenance and operation instructions.

9.4

All documents shall be in English Language.

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR PIG SIGNALERS

DOCUMENT NO. S-04-02-018

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STANDARD SPECIFICATION FOR INSULATING JOINTS

GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR INSULATING JOINTS

DOCUMENT NO. S-04-02-019

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CONTENTS
Sl. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 Description SCOPE REFERENCE DOCUMENTS MATERIALS DESIGN AND CONSTRUCTION INSPECTION AND TESTS TEST CERTIFICATES PAINTING, MARKING AND SHIPMENT GUARANTEE DOCUMENTATION

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STANDARD SPECIFICATION FOR INSULATING JOINTS

DOCUMENT NO. S-04-02-019

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1.0

SCOPE This specification covers the basic requirements for design, manufacture, testing and supply of carbon steel insulating joints to be installed in onshore pipeline systems handling Natural Gas. REFERENCE DOCUMENTS 2.1 Reference has been made in this specification to the latest edition of following Codes, Standards and Specifications. a) b) c) d) e) f) g) ASME B 31.8 (Gas Transmission & Distribution piping System) ASTM A 370 (Mechanical testing of Steel Product) ANSI B 16.25 (Butt Welding Ends) ASME Section Boiler & pressure Vessel Code viii & ix API 1104 (Standard for welding pipelines and related facilities) SSPC-VIS-1 (Steel Structures painting Council Visual Standard) MSS-SP-53 (Quality standard for steel castings and forgings for valves flanges and fittings and other piping components - magnetic particle examination method) MSS-SP-75 (Specification for high test wrought welding fittings) NACE RP 0286 (Standard for electrical isolation of cathodically protected pipelines) In case of conflict between the requirements of this specification and any code, Standard or Specification referred to in this Specification, the requirements of this specification shall govern. the

2.0

h) i) 2.2

3.0

MATERIALS 3.1 Material for the pressure containing parts of the insulating joints shall be as indicated in the data sheets. Material for pups shall be equivalent or superior to the material of connecting pipeline which is indicated in the data sheets. Other part shall be as per manufacturer's standard suitable for the service condition indicated in Insulating Joint Data Sheets and shall be subject to approval by Purchaser. Insulating joints, which are subject to field welding by purchaser, shall have carbon equivalent (CE) not exceeding 0.45 based on check analysis for each heat of steel calculated according to the following formula:
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3.2

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STANDARD SPECIFICATION FOR INSULATING JOINTS

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CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15 3.3 When specified in the IJ Data Sheet, charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of 0 C. The charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Average impact energy value of three full sized specimens shall be 27 joules. Minimum impact energy value of any one specimen shall not be less than 80% of the average impact energy specified. No specimen shall exhibit less than 80% shear area. Carbon steel used for the manufacture shall be fully killed When specified in data sheet, hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise. Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286.

3.4 3.5

3.6 4.0 4.1

DESIGN & CONSTRUCTION REQUIREMENTS Mechanical 4.1.1 Insulating joints shall be of integral type fabricated by welding and with pups on either side as shown in data sheet. A corrosion allowance as indicated in data sheet shall be considered in design. Bolted and threaded joints are not acceptable. 4.1.2 All materials used for the manufacture of the insulating joint shall be in accordance with clause 3.0 of this Specification. 4.1.3 Insulating joints shall be designed using the design principles of ASME Section- VIII Div. 1. The design shall be checked for the following two cases: Case-I: Design Pressure (as per Data Sheet) + Axial Force (F) The Axial force shall be calculated as under: F = 0.1 x S x A Where S = SMYS of connected pipe (refer Data Sheet) A = Metal cross-sectional area of connected pipe. The allowable stress in this case shall be less than or equal to 0.5 x SMYS of insulating joint material.
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Case-II: Hydrostatic Test Pressure The allowable stress in this case shall be less than or equal to 90% of SMYS of insulating joint material. All design parameters shall be as per Insulating Joint Data Sheet. Detailed calculations shall be submitted for Purchaser approval. 4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to 1 millibar. 4.1.5 The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld design shall be such as resulting in a weld joint factor of 1.0. 4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding ends having unequal thickness with respect to connecting pipe, shall be as per ASME B31.4/ B31.8 as applicable. 4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed for a distance of at least 50mm from each end. 4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal bore shall be same as that of connecting pipe including its tolerances. 4.1.9 The insulating joint shall be formed by sandwiching and locking in positions the insulating material in a bell and spigot type of joint. The joint shall be assembled in such a way that its various components are firmly locked in position and the completed joint is capable of withstanding stresses due to designed operating conditions and field hydrostatic testing. 4.1.10 Insulating joints shall be suitable for aboveground or underground installations as indicated in the data sheets. 4.1.11 All welds shall be made by welders and welding procedures qualified in accordance with the provisions ASME section IX. The procedure qualification shall include impact test and hardness test and shall meet the requirements of clause 3.3, 3.5 of this specification. 4.1.12 Repair welding on parent metal is not allowed. Repair of welds shall be carried out only after specific approval by purchaser's representative for each repair. The repair welding shall be carried out by welders and welding procedures duly qualified as per ASME section IX and records for each repair shall be maintained. 4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm from the nominal internal diameter.
GAIL (INDIA) LTD NEW DELHI STANDARD SPECIFICATION FOR INSULATING JOINTS DOCUMENT NO. S-04-02-019 REV-0 Page 5 of 9

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4.1.14 Out of roundness measured at the root face of the welding ends shall not be more than 0.5% of the specified inside diameter. 4.2 Electrical 4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts. 4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either side of the insulating joint for connecting 10 mm2 and 50 mm2 cables for measurement/ shorting purposes. Cleats shall be attached to the insulating joint by welding. 5.0 INSPECTION AND TESTS 5.1 The manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment at his works. Such inspection and tests shall be, but not limited to the following: 5.1.1 All insulating joints shall be visually inspected 5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings 5.1.3 Chemical composition and mechanical properties including hardness shall be checked as per relevant material standards and this specification, for each heat of steel used 5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below: a) 100% radiography shall be carried out on all butt & repair welds of pressure containing parts. Acceptance limits shall be as per API 1104. Welds, which in purchaser's opinion can not be inspected by radiographic methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME Section VIII Appendix-12 and Appendix-6 respectively. All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a distance of 50mm from the ends. Any lamination larger than 6.35 mm shall not be acceptable. All forgings shall be wet magnetic particle inspected on 100% of forged surfaces. Method and acceptance shall comply with MSS-SP53.

b)

c)

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STANDARD SPECIFICATION FOR INSULATING JOINTS

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d)

All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle inspection and 6mm shall be examined 100% by UT. Acceptance criteria for MPI & UT shall be as per ASME Sec. VIII Appendix-6 & Appendix-12 respectively.

5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data sheet. The test duration shall be of 15 minutes 5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage will be accepted. 5.1.7 Dielectric Test a) b) Insulation resistance of each insulating joint shall be at least 25 mega ohms when checked with 500-1000 V DC. Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic test shall be equal. Testing time voltage and leakage shall be recorded and certified. No repair shall be permitted to the insulating joints failed in the above mentioned tests.

5.2

Purchaser reserves the right to perform stage wise inspection and witness test as indicated in Para 5.1 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 purchaser's Representative. Inspection and tests performed/witnessed by the Purchaser's Representative shall in no way relieve the Manufacturer's obligation to perform the required inspection and test.

6.0

TEST CERTIFICATES 6.1 Manufacturer shall Representative. a) submit following certificates to Purchaser's

Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for construction of insulating joint as per this specification and relevant standards. Test reports on non-destructive testing. Test certificates for hydrostatic and air tests. Test certificate for electrical test. Test report on vacuum test.
STANDARD SPECIFICATION FOR INSULATING JOINTS DOCUMENT NO. S-04-02-019 REV-0 Page 7 of 9

b) c) d) e)

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7.0

PAINTING, MARKING AND SHIPMENT. 7.1 Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with "steel structures painting council - Visual standard SSPC-VIS-l". External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for approval. Insulating joints shall be marked with indelible paint with the following data:a. b. c. d. e. f. g. h. 7.3 7.4 Manufacturer's name Suitable for inch nominal diameter pipeline End thickness in mm Material Design Pressure/ Hydrostatic Test Pressure ANSI Class Rating Tag No. Year of Manufacture

7.2

Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel protectors shall be provided to weld ends. Only those insulating joints which have been inspected and certified by Purchaser shall be shipped.

8.0

GUARANTEE 8.1 8.2 8.3 8.4 The manufacturer shall guarantee that the materials used comply with the requirements of this specification. Manufacturer shall replace or repair insulating joints found defective due to inadequate engineering or quality of material. Manufacturer shall replace the insulating joint without delay if the defect or malfunctioning can not be eliminated. Any defects occurring within 12 months from the date of installation or within 30 months from the date of dispatch, whichever is earlier shall be repaired making all necessary modifications and repair of defective parts free of charge to the purchaser.

9.0

DOCUMENTATION 9.1 All documents shall be in English Language.


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9.2

At the time of bidding, Bidder shall submit the following documents:a) General arrangement drawing along with cross sectional view, overall dimensions and details of insulating materials recommended. b) c) Reference lists of previous supplies of insulating joint of similar specification. Clause wise list of deviation from this specification, if any.

9.3

Within three weeks of placement of order, the Manufacturer shall submit four copies of the following drawings, documents and specifications for approval. a) b) c) d) Fabrication drawings and relevant calculations for pressure containing parts. Welding procedure and method of manufacture for all phases of manufacture. Quality Assurance Plan (QAP) Any other Drawing / Document etc. as requested by Purchaser

Once the approval has been given by purchaser, any changes in design, material and method of manufacture shall be notified to the Purchaser whose approval in writing of all changes shall be obtained before the insulting joints are manufactured. 9.4 Within four weeks from the approval date, Manufacturer shall submit one reproducible and six copies of the approved drawings, documents and specifications as listed in 9.3 of this specification. Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test certificates as listed in clause 6.0 of this specification.

9.5

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STANDARD SPECIFICATION FOR INSULATING JOINTS

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GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS

SPECIFICATION S 04 02 - 020

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GAIL (INDIA) LTD NEW DELHI

STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS

SPECIFICATION S 04 02 - 020

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PART A 1.0 SCOPE

CASING INSULATORS

This specification covers the minimum requirements of design, material, manufacture and supply of casing insulators intended to be used for cased pipeline crossings. 2.0 FUNCTION Pipeline insulators shall be used to support the carrier pipe inside the casing pipe and electrically isolate the carrier pipe from the casing pipe at the cased crossings. The casing insulators shall have the following properties: 3.0 Resist cold flow and will not soften at design temperature. Resist corrosion. Resist mechanical damage while being pulled into the casing. Have high electrical insulating value and low water absorption, thus preventing leakage and maintain electrical isolation between carrier and casing pipes. Have high compressive strength in order to ensure a permanent support to the carrier pipe.

DESIGN The arrangement of insulator shall be generally in accordance with Fig. 3.0. It shall be made in segments duly held together with cadmiudXYLAN plated bolts and nuts, to be supplied with casing insulators. The number of segments shall be two for pipe diameters upto DN 300 rnm (12"). For larger diameter, the number of segments may be more than two, but their number shall be kept minimum. The skid height shall be such that it is slightly less than the value obtained by following formula: Casing Internal Dia - Carrier Outer Dia 2 Manufacturer shall obtain prior approval from OWNER on casing insulators drawingsldesign.

4.0

MATERIAL
GAIL (INDIA) LTD NEW DELHI STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS SPECIFICATION S 04 02 - 020 REV-0 Page 3 of 8

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Casing insulators shall be made of injection moulded high density polyethylene or other material, equivalent or superior, as approved by OWNER. The material shall meet the following specifications: Property Dielectric Strength Compressive Strength Tensile Strength Impact Strength Water Absorption
5.0

Value 450 500 Volts/Mil 3200 psi 3100 5000 psi 4.0 ft.lb/ inch of notch 0.01 %

ASTM Test Method D-149 D-695 D-638, D-651 D-256 D-570

INSPECTION AND TESTING Manufacturer shall furnish material test certificates of the components used in the assembly of casing insulators as per the requirements of clause 4.0 of this specification.

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STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS

SPECIFICATION S 04 02 - 020

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PART - B SCOPE

CASING END SEALS

This specification covers the minimum requirements of design, material, fabrication and supply of casing end seals intended to be used for pipeline cased crossings. FUNCTION Casing end seals are intended to be used for sealing the annular space between casing pipe and carrier pipe at casing ends so as to prevent ingress of moisture and water. DESIGN The seals shall be suitable for the casing and carrier pipe diameters as applicable for each case. The casing end seal shall be flexible to cater for the expansion and contraction of carrier and casing pipes and shall be able to tolerate both angular and concentric misalignment of casing pipe without loss of sealing efficiency. The design of the casing end seals shall permit easy installation of the seal to the cased pipeline crossing. It shall provide moisture-proof seals when installed for the entire anticipated life of the buried pipeline. Manufacturer shall obtain prior approval from OWNER on casing end seals design/drawings. MATERIAL The casing end-seals shall be made of heat shrink high density radiation cross linked polyethylene with an adhesive having a melt point suitable for the pipeline service temperature and ambient temperatures foreseen during construction. End seals material shall be resistant to heat, cold, vibration, impact, abrasion, corrosive fluids, disbonding, organic and biodeterioration. Manufacturer shall confirm compatibility of end seals with carrier pipe coating. Casing end seals shall meet following minimum property requirements: a) Backing (Sleeve and closure patch) Property Tensile strength Ultimate Elongation Minimum Value 2200 psi 400 % Test Method ASTM D 638 ASTM D 638
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STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS

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Heat Shock

No Visual Cracks, Flow or Drips at 250C, 4 hours

ASTM D 2671

b)

Adhesive Propertv Ring and Ball Softening Point Lap Shear Minimum Value 90C 60C - 25 psi 23C - 250 psi (2 inchlmin.) Test Method ASTM E 28 ASTM D 1002

c)

System (As Applied) Property Peel strength (To casing and carrier pipe and closure patch) Minimum Value 5 pli (1 0 inchlmin.) Test Method ASTM D 1000

5 .O

INSPECTION AND TESTING Manufacturer shall furnish material test certificates of the components used in the assembly of casing end seals as per the requirements of this specification.

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STANDARD SPECIFICATION FOR CASING INSULATORS AND END SEALS

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PART - C 1.0 2.0

SUPPLEMENTARY REQUIREMENTS

The manufacturer shall replace, at no extra cost, any material not conforming to the material and performance requirements of this specification. Manufacturer shall submit detailed specification of the materials used in the assemblies, along with instructions for handling, use and installation of the material for OWNER approval prior to procurement. Manufacturer shall submit all the documents, test reports, records and other information to OWNER for record after approval as per clause 2.0 above. Number of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.

3.0

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SPECIFICATION S 04 02 - 020

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPELINES)

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

SPECIFICATION S-04-02-021

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

SPECIFICATION S-04-02-021

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

SPECIFICATION S-04-02-021

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1.0

SCOPE This specification establishes the minimum requirements of materials, equipment and installation of field joint anti-corrosion coating of buried onshore pipelines factory coated with either three layer polyethylene or fusion bonded epoxy coating, by heat shrink wraparound sleeves or by cold applied tapes conforming to DIN EN 12068 "Cathodic Protection - External Organic Coatings for the Corrosion Protection of Buried or Immersed Steel Pipelines used in Conjunction with Cathodic Protection - Tapes and Shrinkable Materials" and the requirements of this specification. Unless modifiedlreplaced by this specification, all requirements of DIN EN 12068 shall remain fully applicable and complied with. This specification shall be read in conjunction with the conditions of all specifications and documents included in the Contract between Company and Contractor. Unless specified otherwise, all sections of this specification shall apply to all specifications referred in this specification.

1.1

2.0

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

a)

ASTM D- 149

Standard Test Methods of Dielectric Breakdown voltage & Dielectric strength of solid electrical insulating materials at commercial frequencies. Standard Test Methods for D-C Resistance or conductance of insulating materials. Standard Method of Test for Water Absorption of Plastics. : Preparation of Steel Substrates before Application of Paints and Related Products -Part 3 - Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method)

b)

ASTM D-257

c) d)

ASTM D-570 IS0 8502 3

e)

ISO 8503 1

Part 1: Specification and definitions for IS0 surface profile comparator for the assessment of abrasive blast cleaned surfaces.
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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

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f)

ISO 8503 4

Part 4: Methods for calibration of IS0 surface profile comparator and for the determination of surface profile Stylus instrument procedure. Pictorial Surface Preparation Standard for Painting Steel Surfaces. Steel Structure Painting Council

g) h)

SIS 055900 SSPC-SP 1

: :

In case of conflict between the requirements of this specification and that of above referred documents, the requirements of this specification shall govern. The CONTRACTOR shall be familiar with the requirements of these documents and shall make them readily available at the site to all personnel concerned with carrying out the works specified in this specification.
3.0

MATERIALS AND EQUIPMENT Field joint anti-corrosion coating material shall be either heat shrinkable wraparound sleeve or cold applied tape suitable for a maximum operating temperature of (+) 60C (Tmax) and shall conform to designation EN 12068 - C HT 60 UV. In addition, the field joint anti-corrosion coating shall comply the requirements specified in para 3.2 of this specification.

3.1

3.1.1 Heat shrinkable wraparound sleeves: Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized,Ultra violet resistant semi-rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing shall be provided with suitable means (thermo-chrome paint, dimple, or other means) to indicate the desired heat during shrinking in field is attained. The sleeve shall be supplied in pre-cut sizes 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 as follows:
Pipe Size (Specified Outside Diameter) 30" (762 mm) 32'' (813.0 mm) Average 2.0 2.4 Thickness (mm) On Pipe Body Min. 1.8 2.2 On Weld Bead (Min.) 1.6 2.0

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

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The heat shrink wraparound sleeve shall have the required adhesive properties when applied on various commercial pipe-coating materials. The pre-heat and application temperatures required for the application of the shrink sleeve shall not cause loss of functional properties of the pipe coating. Heat shrinkable wraparound field joint coating system manufactured by M/S Tyco Adhesives Raychem and M/S Canusa are acceptable for the supply of field joint coating materials. The Contractor shall propose the specific grade of field joint coating system meeting the requirements of this specification from these manufacturers. In case the Contractor proposes to supply heat shrinkable wraparound sleeve from any other manufacturer, then the Contractor shall propose only those coating systems that have been previously used for pipelines of size same or higher than the size indicated in tender, for a length of 50 Km and above in a single project for similar operating conditions. 3.1.2 Cold Applied Tapes: Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap. The inner and outer wraps shall be asymmetric 3-ply tape with co-extruded polyethylene carrier film and butyl rubber adhesive layers on both sides. The inner layer of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. The inner and outer wraps are to be spirally wrapped with 55% overlap, equivalent to two layers each providing a total minimum thickness of 3.0 mm on the pipe body and 2.5 mm on the weld. The Contractor shall propose only those cold applied tape coating systems that have been previously used in pipelines of size 16" and above and a length of 50 km and above in a single project 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. a. b. c. d e. PROPERTIES Tensile Strength @ + 25 0C Ultimate Elongation @ + 25 0C Dielectric Withstand with 1000 Volts/Sec Water absorption @ +25 0C for 24 Hours Volume Resistivity @ +25 0C UNIT N / mm2 % KV % Ohm-cm
REQUIREMENT

TEST METHOD DIN EN 12068 DIN EN 12068 ASTM D 149 ASTM D 570 ASTM D 257

12 250 0C 30 0.05 1015

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

SPECIFICATION S-04-02-021

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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, Table 1 and 2 corresponding to designation DIN EN 12068 - C HT 60 W, except as modified below:

a) b)

Cathodic Disbondment Resistance at Tmax i.e 60C shall be 20 mm when tested as per Annexure K of DIN EN 12068. Test shall be carried out at (+) 60C Peel Strength shall be as follows : Peel Strength
Inner to Inner (+) Outer to Inner Outer to Outer @ 23 0C @ Tmax @ 23 0C @ Tmax To pipe surface @ 23 0C @ Tmax To Factory Coating @ 23 0C @ Tmax

Unit
N/mm N/mm N/mm N/mm N/mm N/mm N/mm N/mm

Requirement for Mechanical Resistance Class C (minmum) 1.5


0.3 1.5 0.3 3.5 0.5 3.5 0.5

Test Method as per DIN EN 12068 ANNEXURE - B

ANNEXURE - C

Tmax shall be (+) 60 0C

Contractor shall obtain prior approval from Company regarding the Manufacturer of the joint coating material and the specific grade of the joint coating system. Complete technical details along with test certificates complying with the requirements of clause 3.2.1 and 3.2.2 shall be submitted to Company for this purpose. The Contractor shall finish test certificates from an independent DIN recognized / approved laboratory for all the properties required for the specified EN designation of field joint 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 by the Contractor. Deteriorated/ decomposed material shall be disposed off and replaced by the contractor at his own expenses. Contractor shall ensure that the coating materials supplied by him are properly packed and clearly marked with the following: Manufacturer's name
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3.4

Material qualification Batch number Date of manufacturing and date of expiry

Contractor shall ensure that the Manufacturer has carried out all quality control tests on each batch and manufacturer shall provide test certificates to certify that the supplied materials meet the manufacturer's specifications as indicated in the purchase order and as approved by COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall be submitted by Contractor to Company prior to application. Company reserves the right to have the materials tested by an independent laboratory. Materials shall be stored in sheltered storage in the manufacturer's original packing and away from direct sunlight and in accordance with manufacturer's instructions. Contractor shall provide and maintain mobile facilities which contain all necessary equipment and its spares for cleaning, coating, repairs, inspection and tests. Contractor shall furnish sufficient number of the following equipment and the required spares as a minimum for inspection and test purposes for each crew: a) b) c) d) Fully automatic full circle adjustable holiday detector with a visible and audible signal system for inspection of coatings. Thickness gauge for measuring thickness. Contact type temperature recording thermometer (Digital Pyrometer with flat probe type contact). Roughness profile measuring (Stylus) instrument

3.5 3.6 3.7

4.0

APPLICATION PROCEDURE General

4.1

4.1.1 The application procedure shall be in accordance with manufacturer's instructions and the minimum requirements specified below whichever are the most stringent and shall be demonstrated to and approved by the Company. Manufacturer's expert shall supervise the application and shall be available at site upon request during qualification of application procedure and during construction at Contractor's cost. 4.1.2 Operators for coating application shall be given necessary instructions and training before start of work, by the Contractor. To verify and qualify the application procedures, all coating applied during the qualification test, shall be removed for destructive testing as detailed subsequently in this specification. Contractor shall only
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utilize those operators who have been approved/ prequalified by the field joint coating manufacturer. 4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed. 4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or an open expendable blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be used and Garnet material with the second one (in case the authority having jurisdiction have no objection, the contractor may adopt sand blasting instead of garnet material). During blast cleaning the pipe surface temperature shall be simultaneously more than 5 0C and more than 3C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than 85 %. Prior to surface cleaning the surfaces shall be completely dry. The surface shall be cleaned to a grade Sa 2 in accordance with Swedish Standard SIS-055900 with a roughness profile of 50 - 70 microns. Surface roughness profile shall be measured using an approved profile comparator in accordance with IS0 8503-1 and shall be calibrated prior to the start of the work in accordance with IS0 8503-3 or IS0 8503-4. The blast cleanliness shall be checked on 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 vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per IS0 8502 -3. The frequency 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 % Relative Humidity (RH) 70 - 80 % Relative Humidity (RH) < 70 % - 2 hours - 3 hours - 4 hours

Pipe delayed beyond this point or pipes showing any visible rust stain, shall be blast cleaned again.
4.1.5

The field joint surface shall be inspected immediately after blast cleaning and any feature of the steel surface such as weld spatter, scabs, laminations or other imperfections considered injurious to the coating integrity, made visible during blast cleaning, shall be reported to the Company Representative and on permission from Company Representative, such defects shall be removed by filing or grinding. Pipes affected in this manner shall be then re-blast cleaned if 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. Unbounded portions of the coating shall be removed and then suitably trimmed.
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Portions where parent coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating. 4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the coating in order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter. All these substances shall be removed before coating, to the procedures herein described. 4.1.8 Protection coating shall be applied on the joints immediately after the completion of cleaning operation. 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 mill coating for the leading edges of the joints shall be minimum 200 mm. When this extra overlap is achieved by providing an additional patch of heat shrink tape/ wraparound, it shall be applied in such a manner that the square edge of the patch on the joint coating is in the direction opposite to the direction of boring / jacking. 4.2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated either with a torch moved back and forth over the surface or by induction heating. The minimum pre-heat temperature shall be as recommended by manufacturer and shall be checked by means of contact type temperature-recording thermometer (Digital Pyrometer with flat probe type contact). Temperature indicating crayons shall not be used. Pre-heat temperature shall be checked on every joint. Care shall be taken to ensure that the entire circumference of the pipe is heated evenly. Temperature measuring instruments shall be calibrated immediately before the start of the works and thereafter at intervals recommended by the manufacturer of the instrument. 4.2.3 Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet film thickness 150 microns or as per manufacturer's recommendation whichever is higher, to cover the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating if recommended by the manufacturer. The wet film thickness of the primer shall be checked on every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall be calibrated once per shift.

4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be entirely wrapped around the pipe within the stipulated time recommended by the manufacturer. Sleeve shall be positioned such that the closure patch is located to one side of the pipe
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in 10 or 2 O'clock position, 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 it firmly into place. 4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start shrinkage of the sleeve beginning from the center of the sleeve and heat circumferentially around the pipe. Continue heating from the center towards one end of the sleeve until recovery is completed. In a similar manner, heat and shrink the remaining side. Shrinking has been completed 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 of existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The installed sleeve shall not be disturbed until the adhesive has solidified. 4.3 Application Procedure for Cold Applied Tapes

4.3.1 Cold applied joint protection tape shall be of the type, which can be applied by spiral wrapping on the pipe. 4.3.2 Immediately after the completion of surface preparation, the approved primer of wet film thickness 150 microns or as per manufacturer's recommendation whichever is higher, to cover the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating if recommended by the manufacturer. Any dirt on the primed surface shall be removed. If the primer is damaged, the damaged area shall be cleaned and re-primed. 4.3.3 Approximately 100 mm of inner wrap interleaving paper shall be peeled back and inner wrap shall be applied with the thicker adhesive side to the pipe. Whilst continuously removing the interleaving paper, the tape shall be spirally applied through a machine to provide a minimum of 55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air pockets and also continuously smooth out as the wrapping proceeds. The wrapping shall start and finish to give a minimum 50 mm overlap on to the adjoining yard applied coating. Outer wrap shall also be applied in similar method. 4.4 Pre-Qualification of Field Joint Coating System The field joint coating system materials and the procedures proposed by the Contractor shall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shall be coated with the requirements of this specification and then inspected and tested in accordance with the requirements of this specification with respect to the following: (i) (ii) Surface preparation, cleanliness, roughness profile and dust contamination Pre-heat temperature (as applicable)
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(iii) (iv) (v) (vi)

Primer thickness As applied coating thickness Holiday detection Peel test at (+) 23C & (+) 60C on pipe surface & factory applied coating and at overlaps (as applicable). If required to achieve the temperature of (+) 60C, suitable thermal blanket may be used. Visual appearance and void after installation on the body, area adjoining the weld and area adjoining the factory applied coating. (To establish voids adjoining the weld and factory coating, a strip of 50 mm wide and 200 mm long shall be stripped and examined.)

(vii)

Company Representative shall witness the tests and inspection. Regular application of field joint coating shall commence only upon successful completion of the prequalification testing. After successful completion of the pre-qualification testing as above, the entire field joint coating shall be removed, the pipe surface re-blasted and field joint coating reapplied as per the requirements of this specification. 5.0 5.1 INSPECTION AND TESTING Visual Inspection Visual inspection of the as applied coating shall be carried out on every joint, for the following: (i) (ii) Mastic extrusion on either ends of the sleeve shall be examined 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. All sleeves shall be tested for the presence of voids by knocking on the sleeves. A hollow sound compared to the remainder of the sleeve may indicate the presence of voids under the sleeve. Such sleeve shall be tested for adhesion at the discretion of the Company Representative. Weld bead profile shall be visible through the sleeve Visual indicator provided on the backing and the closure patch showing desired heat is achieved.
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(iii) (iv)

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5.2

Holiday Inspection The entire surface of each joint shall be inspected by means of a full circle holiday detector approved by Company, set to a DC voltage applicable as per the requirements of factory applied mainline coating specification of Company. Inspection of the sleeves shall be conducted only after the joint has cooled below 50C. The holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. No field joint shall be covered or lowered in the trench until it has been approved by the Company.

5.3

As-applied Coating Thickness Coating thickness shall be checked by non-destructive methods for each field joint. Average thickness of the as-applied coating on pipe body shall be established based on measurements at min. eight locations i.e four measurements on either sides of the girth weld at 3, 6, 9 & 12 O'clock positions. To establish the minimum thickness on the girth weld, four measurements shall be taken on apex on the weld at 3, 6, 9 & 12 O'clock positions. All such measurements shall be recorded. Company Representative reserves the right to ask for additional measurements 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 applied coating. 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 25rnrn x 200 mm shall be cut perpendicular to the pipe axis and slowly peeled off. The required peel strength shall meet the requirements of this specification as applicable for (+)23 0C or (+) 60 0C whichever is feasible. This test shall be conducted between wrapping & metal and mill coating & between layers at overlap with joint coating (wherever applicable). After removal of strip, the bulk of adhesive shall remain adhered to the pipe showing no bare metal, otherwise, test shall be considered failed. The adhesive layer that remains on the pipe surface shall generally be free of voids resulting from air or gas inclusion. In case the peel strength test at a different temperature than that specified is warranted due to the ambient site conditions, then the peel strength shall comply the recommendation of the manufacturer. Manufacturer shall be asked to furnish peel strength values corresponding to various expected temperatures, prior to start of the works.
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5.4.3 If the sleeve does not meet the requirements of clause 5.4.2, the adjacent two sleeves shall also be tested. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve every twenty five until Company's Representative is satisfied. The test rate can then be reduced as per clause 5.4.1 at discretion of Company's Representative. If either or both of the adjacent two sleeves do not meet the requirements of clause 5.4.2, the field coating shall be stopped. 5.4.4 Company Representative reserve the right of 100% removal of sleeves if he is not convinced that the requirements of clause 5.4.2 are achieved. 6.0 6.1 REPAIRS If a field joint is detected to be unacceptable after testing as per section 5.0 of this specification the Contractor shall, at his own cost: (i) (ii) (iii) (iv) 6.2 6.3 6.4 Determine the cause of the faulty results of the field coating. Mobilise the expert of manufacturer, if required. Test to the complete satisfaction of Company, already completed field coatings. Stop the field coating works until remedial measures are taken against the causes of such faults, to the entire satisfaction of the Company.

Contractor shall replace all joint coating found or expected to be unacceptable as per section 5.0 of this specification. Contractor shall, at his own cost repair all areas where the coating has been removed for testing by the Company. After the coating work on welded joints and repairs to the coating have been completed the coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline. Company shall be entitled to check the coating on buried pipelines or parts of pipelines with equipment such as the "Pearson Meter" and the resistance meter. If coating defects are established, the Contractor shall be responsible for excavation at such points, repairing the coating, spark testing and backfilling the excavations without extra charge. DOCUMENTATION Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the Manufacturer and material: a. Complete information as per clause 3.2 and DIN EN 12068 along with descriptive technical catalogues.
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6.5

7.0 7.1

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b. c.

Test certificates and results of previously conducted tests, for all properties listed in clause 3.2 of this specification. Reference list of previous supplies, in last 5 years, of the similar material indicating the project details such as diameter, quantity, operating temperature, year of supply, project name, contact person and feed back on performance. Once the Company's approval has been given, any change in material or Manufacturer shall be notified to Company, whose approval in writing of all changes shall be obtained before the materials are manufactured.

7.2

Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish the following documents: a. b. c. Test certificates / results as per Manufacturer's Quality Control Procedure for each batch of materials. Specific application instructions with pictorial illustrations. Specific storage and handling instructions.

7.3

All documents shall be in English language only.

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STANDARD SPECIFICATION FOR FIELD JOINT COATING (ONSHORE PIPEINE)

SPECIFICATION S-04-02-021

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STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINES

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STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINE

SPECIFICATION S-04-02-022

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STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINE

SPECIFICATION S-04-02-022

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STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINE

SPECIFICATION S-04-02-022

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1.0 1.1

SCOPE This specification covers the minimum requirements for the materials, application, inspection, handling and other activities for external concrete weight coating of pipelines. This specification shall be read in conjunction with the conditions of all specifications and documents included in the CONTRACT between Company and Contractor. Contractor shall, with care and diligency, execute the work in compliance with all laws, bylaws, ordinances, regulation, etc. and provide all services and labour, inclusive of supervision thereof, all materials, excluding the materials indicated as Company supplied materials in the CONTRACT, equipment, appliances or other things of whatsoever nature required in or about the execution of the work, whether of temporary or pemanent nature. Unless otherwise specified, all sections of this specification shall apply to all the specification referred in this specification. REFERENCE DOCUMENTS Reference has been made in this specification to the latest edition (edition enforce at the time of issue of enquiry) of the following codes and specifications: IS-269 IS-383 : : Indian Standard Specification for Ordinary Portland Cement. Indian Standard Specification for Coarse And Fine Aggregates From Natural Sources For Concrete. Indian Standard Methods of Test for Aggregates for Concrete. thru' VIII) Indian Standard Specification for High Strength Ordinary Portland Cement. Specification for Steel Wire, Plain, for concrete Reinforcement. Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement Specification for Zinc Coated (Galvanized) Carbon Steel Wire.
SPECIFICATION S-04-02-022 REV-0 Page 4 of 15

1.2 1.3

1.4 2.0 2.1

IS-2386 (Parts-I IS-8 1 12 ASTM A-82 ASTM A-1 85 ASTM A-64 1

: : : : :

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STANDARD SPECIFICATION FOR CONCRETE WEIGHT COATING OF ONSHORE PIPELINE

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ASTM C-39 ASTM C-138 ASTM C-309 ASTM C-642

: : : :

Test Method for Compressive strength of cylindrical concrete specimens. Test Method for Unit weight, Yield and Air Content of Concrete. Specification for Liquid Membrane Forming Compounds for Curing Concrete. Test Method for Specific Gravity, Absorption and Voids in Hardened Concrete.

In case of conflict between the requirements of this specification and that of the above referred codes and standards, the requirements of this specification shall govern. The Contractor shall be familiar with the requirements of these documents and shall make them readily available at the coating plant. 2.2 For the purpose of this specification, the following definition shall hold: 3.0 the words 'Shall' and Must' are mandatory; the words 'Should', 'May' and 'Will' are non-mandatory, advisory or Recommended.

MATERIALS The Contractor shall supply all the materials necessary for the performance of the work. Materials for concrete weight coating shall comply with the following requirements. All the materials supplied by the Contractor, which in the opinion of Company's Representative / Inspector, do not comply with the appropriate specifications, shall be rejected and removed from the site.

3.1

Cement Portland Cement (conforming to IS-269), or High Strength Ordinary Portland Cement (conforming to IS-81 12) shall be used. Cement which has hardened or partially set or which has become lumpy shall not be used. Test certificates form the cement Manufacturer shall be supplied to the Company for all cement delivered to site. In case concrete weight coating is to be provided at locations affected by sea water tidal flats etc., Portland cement in accordance with ASTM C-150 Type III shall be used.

3.2

Aggregates
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3.2.1 Aggregates shall comply with the requirements of IS:383 and shall be tested in accordance with IS:2386. 3.2.2 Fine Aggregates 'Fine Aggregates' shall mean any of the following, as defined in IS:383: i) ii) iii) Sand Natural sand; Crushed stone sand; Crushed gravel sand. shall be well graded from fine to coarse in accordance with Table 4 of IS:383.

3.2.3 Coarse Aggregates Use of coarse aggregates shall be subject to Company approval. 3.2.4 Aggregates (fine and coarse) shall be clean and free from clay and injurious amounts of salt, alkali, deleterious substances or organic impurities. 3.3 Water The water shall be fresh and clean and shall be free from injurious amounts of oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It shall not contain chlorides, sulphates, and magnesium salts. Water from each source shall be tested prior to its use and shall be approved by Company. Seawater or contaminated water shall not be used. Water from doubtful sources shall be tested by the Contractor at his expanse and approved by Company before use. 3.4. Reinforcement Concrete coating shall be reinforced by a layer or layers of steel reinforcement according to the provisions hereinafter described. 3.4.1 Reinforcement shall consist of welded steel wire fabric manufactured in flat sheets or in rolls (ribbon mesh) and shall conform ASTM A-185. Wires shall conform to ASTM A-82.

3.4.2 Steel wire shall be galvanised at finished size as per ASTM A-641. The diameter of the wire and spacing of wires (mesh dimensions) shall be selected according to the following criteria. 3.4.2.1 Wire fabric manufactured in flat sheets shall be 2 x 4 inches max. Steel wire mesh, 13 gauge U.S. Steel wire (2.4 mm) min. each way.

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3.4.2.2 Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. Steel wires (2mm wire). The above dimensions will be applied unless otherwise specified by designs. As a rule wire fabric (sheets) shall be used when concrete coating is applied by casting method, while ribbon mesh (rolls) shall be used when concrete coating is applied by impingement method. 4.0 COATING REQUIREMENTS Pipes shall be concrete coated to a thickness and density as specified in the drawings and CONTRACT documents. The concrete unit weight shall be minimum 2245 kg/m3 (140 pounds per cubic foot) and the compressive strength shall not be less than 200 kg/cm2 in 28 days and 135 kg/cm2 in 7 days. Concrete coating shape shall be circular and concentric to pipe outside diameter. Other concrete coating shapes are not acceptable. 5.0 APPLICATION METHOD Concrete coating shall be applied either using casting or impingement method. Any alteration or modifications to the methods described in this specification shall be submitted to theCompany for approval. The application method shall however ensure the basic characteristics of concrete coating in compliance with the minimum requirements of this specification. Contractor shall submit to the Company, prior to commencement of work, the Procedure / method of application for approval. Wherever practical, the total thickness of coating shall be applied in a single pass. 6.0 EQUIPMENT The equipment used for performing the concrete coating shall be capable of doing so with a required degree of uniformity with respect to thickness, density and strength. The proportioning equipment and procedure shall be of the type to assure consistently proportioned material by weight. Concrete shall be mixed in a mechanical mixer, which shall ensure thorough mixing of all materials. Any equipment that tends to separate the ingredients shall not be used. 7.0 7.1 MEASUREMENTS AND LOGGING All measurements as mentioned below shall be taken during the work stages and clearly logged in a logbook. A special logbook shall be used for recording tests and trial results. A logbook shall refer to pipe lengths having the same nominal diameter, and steel wall thickness. The following shall be subject to measurement and logging for each pipe length :
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7.2

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a)

Line Pipe 1) Field identification number * 2) Mill serial number * 3) Length * 4) Weight * 5) Outside diameter, mm & Wall Thk, mm (F) (M) (L) (BW) (OD) / (WT)

b)

Corrosion coating ** 6) Type of coating ** 7) Thickness of corrosion coating, mm 8) Weight of coated pipe, kg ** 9) Presence of anode (Yes or No) ** 10) Date of Corrosion Coating Application (C) (CT) (CW) (A) (DCC)

c)

Concrete Coating 11) Batch identification number 12) Date of placing the concrete coating 13) Average concrete coating thickness, mm 14) "Dry Weight" of concrete coated pipe (Weight and date of weighing or Related Weight 28 days after placing of concrete and so identifiable) 15) "Unit dry weight" of concrete coated pipe 16) "Negative Buoyancy" (unit) of concrete (NB) Coated pipe (B) (T) (CCT) (DW)

(UDW)

*Data can be obtained from Pipe Mill tally Sheets. ** Data can be obtained from Coating Plant Tally Sheets. 7.3 8.0 No concrete placing shall be allowed before items 1 through 10 listed at clause 7.2, have been logged. PROCEDURE QUALIFICATION Before commencement of the work, Contractor shall perform all tests, either in laboratory or in field and trials necessary to properly select type of mix, which meets the requirements of this specification. 8.1 The type of mix, i.e. the correct combination of the cement, aggregates and water which results in the desired properties of concrete shall be at first determined for each mix and following shall be accurately checked and recorded:
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- proportion and weights of the respective materials used; - the water / cement ratio; - the grading of the aggregates. 8.2 Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry specific gravity of the concrete. In parallel, test according to ASTM C-138 shall be performed so as to determine the expected correlation between concrete weight after placing and dry specific gravity (28 days after placing). Test for concrete specific gravity at Intermediate time (7 days after coating) shall be performed. When the results of the above tests do not meet the requirements, the mix shall be modified and concrete samples tested until a proper mix has been determined. The mix so determined, shall then be used for sampling of concrete to be submitted to compressive strength tests as per ASTM C39. Frequency of sampling for tests for density and compressive strength of concrete shall be as follows: Quantitv" of Concrete in the Work (m3) Upto 25 26 to 50 5 1 and above Number of Samples 3 4 4

8.3 8.4 8.5

plus one additional sample for each additional 50 m3 or part thereof.

'Quantity' means the volume of concrete to be used for each qualified mix. 9.0 9.1 9.2 APPLICATION OF REINFORCEMENT AND CONCRETE COATING Two test cubes each per day shall be obtained from batches and tested at the end of 7 days after coating, for compressive strength and specific gravity. The moisture content of the aggregates used shall be such as to maintain a satisfactory control on the water / cement ratio of the concrete mix. To maintain the waterlcement ratio constant at its correct value, determination of moisture contents in both fine and coarse (if used) aggregates shall be made as frequently as possible, the frequency for a given job being determined by the Engineerin-Charge according to weather conditions.
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9.3

Pipe Length Preparation Prior to placing of reinforcement, the anti-corrosion coating of each pipe length shall be carefully inspected visually and by holiday detectors and, if damages are found, they shall be repaired in accordance with the relevant specification, before start of the work. Foreign matters, if any, shall be removed from the surface of the anti-corrosion coating.

9.4

Reinforcement Application

9.4.1 Reinforcement shall be placed around the pipe in such a way as to cover the whole pipe length or sections to be concrete coated. The reinforcement shall not protrude beyond the concrete coating ends. 9.4.2 Reinforcement shall rest on synthetic resin or concrete/ RCC spacers forming a "Crown" whose number shall be such as to avoid any contact with the pipe's protective coating. Spacing between the two consecutive "crown" centres shall be 500 to 1000 mm. 9.4.3 Splices and attachments shall be done by binding with steel wire having 1.5 mm diameter. Circular and longitudinal joints of wire fabric in sheets shall be lapped at least for one mesh. When wire fabric in rolls (ribbon mesh) is used, the spiral lap shall be one mesh while and spliced lap shall be three meshes. 9.4.4 One layer of reinforcement steel shall be provided for concrete thickness less than 50 mm. The reinforcing steel shall be embedded approximately midway in the concrete coating thickness. For concrete thickness 50 mm and above two layers of reinforcing steel shall be provided. If application method requires more than one pass concrete, one reinforcement layer for each pass is to be applied independently from concrete coating thickness. In case of one layer of reinforcement, it shall be located approximately in the middle of the concrete thickness. In case of two layers of reinforcement, layers shall be located at 1/3rd and 2/3rd of the concrete thickness. In case of three layers of reinforcement, layer shall be located at 1/4th , 1/2 and 3/4th of concrete thickness. Contractor shall demonstrate that the procedure used ensures no physical contract between steel reinforcement and the pipe and the reinforcement is placed in position as mentioned above. 9.5 Concrete Placing

9.5.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (i.e. after adding water to mix) and shall be handled in such a way so as to prevent
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aggregate segregation and excessive moisture loss. Concrete containers shall continuously be kept clean and free from hardened or partially hardened concrete. 9.5.2 If casting method is used, once reinforcement and mould have been applied around the pipe, concrete mixture shall be poured through an opening on the upper section of the same mould. Concrete shall not be deposited from a height greater than 1 metre. During pouring of concrete, vibrator sets applied inside of pipe or outside the mould shall vibrate the mix so as to obtain the best possible compactness. 9.5.3 If impingement method is used, placement of concrete shall be up to the specified thickness in one continuous course, allowance being made for splices of reinforcement and providing reinforcement in the right location. Concrete shall be projected at high velocity against the external surface of pipe, to produce a hard, tight-adhering coating of the specified thickness. 9.5.4 No casting shall be interrupted or passes shall be stopped for more than 30 minutes. Before placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and wetted to obtain a good bond between the fresh material and the previously placed material. 9.5.5 Suitable means shall be provided to ensure that the temperature of the concrete, when placed, does not exceed 32C. 9.5.6 All pipes shall be kept clean and free from cement concrete and grout either inside or outside of the uncoated sections. 9.5.7 Bevel protectors shall be kept in place throughout the coating application and after. 9.5.8 The coating at each end of the pipe shall be bevelled to a slope of approximately twoto-one (2: 1). It shall terminate about 50 mm short of the end of the corrosion coating applied on the pipe surface. 9.6 9.6.1 Curing Immediately after concreting, the exposed surfaces of the concrete shall be protected during hardening from the effects of sunshine, drying winds, rain, etc. and then after the initial set has taken place, the concrete coating shall be properly cured. The coated pipe sections shall be handled gently by suitable means to prevent undue distortion.

9.6.2 Curing shall be performed by application of an approved curing membrane using sealing compounds and shall meet the requirements of ASTM C-309. The material shall be stored, prepared and applied in strict conformity with the instructions of the Manufacturer. The ingredients of any such compound shall be non-toxic and noninflammable and shall not react with any ingredient of the concrete, the reinforcement, protective coating or pipe. The application of the curing compound shall take place
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immediately after the coating is completed and preferably before the pipe is removed from the concrete coating apparatus. The surface of the concrete shall be lightly sprayed with water before applying the curing compound. The membrane curing period shall not be less than 4 days, during which period the freshly coated pipes shall not be disturbed. The pipe surface shall be kept wet during daylight hours for seven days after application of the concrete coating. The concrete coating shall not be allowed to dehydrate. Curing of concrete coating may also be done by using jute bags, provided continuous wetting is ensured by the Contractor. 9.6.3 Before handling and hauling the concrete coated pipes, a check shall be made to make sure that the concrete coating is properly cured. Stacking and shipment of the coated pipe shall be initiated only after seven days provided that the concrete coating suffers no damage. 10.0 TOLERANCES 10.1 Contractor shall maintain a surface tolerance of 8 mm (5/16") maximum for the radial distance between high and low areas of the surfaces. The diameter of each coated pipe shall be obtained at three (3) or more points, spaced at equal intervals between the end points. The acceptable weight tolerance for any single pipe shall be limited to plus five (5) or minus two (2) percent of the calculated theoretical weight. The theoretical weight shall be calculated using total weight of the pipe with concrete and corrosion coating.

10.2

11.0 WEIGHING 11.1 11.2 The test specimen shall be selected at equal intervals during the course of production. Contractor shall weigh each pipe when dry prior to shipment and 28 days after placing of concrete and mark the weight with paint on the inside of the pipe. The weight mark shall be followed with letters "DW" meaning Dry Weight. In case contractor opts not to weigh the pipe, the contractor shall provide 20% extra concrete coating thickness over the specified concrete thickness at no extra cost and time to Company. The acceptable weight tolerance of any single pipe shall be limited to +5% or -2% of the calculated weight of concrete. Calculated weight shall consider only the weight of concrete coating based on approved concrete density and thickness.

11.3

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In case Contractor opts not to weigh the pipes, the Contractor shall provide 20% extra concrete coating thickness over the specified concrete thickness at no extra cost and time to Company. 12.0 INSPECTION AND TESTS 12.1 After curing, every length of concrete coated pipe shall be non-destructively tested by means such as "ringing" to determine if any suspected defects are present. In case this indicates faulty coating, cores shall be removed form coating and inspected. When defective coating appears from cores, the concrete costing shall be removed from the pipe lengths. Every length of concrete coated pipe shall be checked to verify insulation between steel reinforcement and pipe by means of a megger or equivalent device. To this purpose provisions should be made during placing of concrete such as to leave at least a point of exposed steel reinforcement whenever the latter shall terminate inside of concrete coating. During the tests as per clause 12.2 above, and before transporting of concrete coated pipes, every pipe length shall be visually inspected to detect whether any damages and / or defects are present. Possible damages and/or defects with their allowable limits are described at following clause 14.0. Repairable concrete coatings shall be clearly marked while the non-repairable once shall be removed from the pipe lengths.

12.2

12.3

13.0 REPAIRS The following repairs are permitted to coating due to unavoidable damage in handling and in storage (This applies only to concrete that has hardened). 13.1 Spalling due to compression or shearing caused by impact against other objects. Spalling is defined as damage, which causes a loss in concrete of more than 25 % of the total thickness of the coating at the point of damage. Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the remaining concrete is sound and reinforcement steel is not exposed, will be accepted without repairs. Damage due to spalling of an area of less than 0.1 m2 with reinforcement exposed; and area more than 0.1 m2 and less than 0.3 m2 shall have the concrete remaining in place over that area removed as necessary to expose the reinforcing steel throughout the damaged area. Edges of the spalled area shall be under-cut so as to provide a key lock for the repair material. A stiff mixture of cement, water and aggregate shall be trowelled into and through the reinforcement and built up until the surface is level with the coating around the repair. The pipe shall then be carefully laid with the repaired
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13.2

13.3

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area at the top and shall be moist cured for a minimum of thirty six (36) hours before further handling. 13.4 Should the damaged area be more than 0.3 m2, coating shall be removed around the entire damaged area. A repair shall be made by satisfactorily restoring the reinforcement, forming the area with a metal form and pouring a complete replacement of materials similar to that from which the coating was made. The mixture shall be one (1) part of cement to three (3) parts of aggregate and the necessary water to produce a slump not to exceed 100 mrn (four inches). The resulting coating shall be equal in weight, density, uniformity, thickness, strength and characteristics to the originally applied coating. The pipe shall then be carefully laid in a position where it shall be allowed to remain for a minimum of 36 hours before furtherhandling.

14.0 MARKING 14.1 Every concrete coated pipe length shall be clearly marked by a suitable type of paint (i.e. red and/or white lead paint). Markings of concrete coating shall be made inside of pipe close to bevel end, in such a way that the area involved by welding operations is not affected by paint. For each concrete coated pipe length, at one of the two ends, the field identification number and the date of concrete placing shall be marked, while the dry as well as the wet weight along with number of days after coating shall be marked at the other end. In addition, Contractor shall develop a colour coding (band) system to be marked on the outside surface for easy identification of the coated pipe for each concrete coating thickness, concrete density, pipe diameter, pipe thickness and pipe material variation.

14.2

15.0 HANDLING, UNLOADING, STORING AND TRANSPORTATION 15.1 Once the pipe sections have been taken on charge, the Contractor, complying with provisions of the CONTRACT, shall execute their transport together with other material, either supplied by him or by the Company, from the site of receipt to the coating yard and after concrete coating completion and acceptance, to delivery point at laying field or storage areas as previously established providing each time the necessary storages. Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially due to humidity or other adverse weather conditions, shall be suitably stored and protected. During loading, transport, unloading and hauling of inert aggregates, any contact and mixing with mud, earth, grease and any other foreign material shall be carefully avoided. Precautions shall be taken to prevent contamination, to maintain the cleanliness and against effects of hot or cold weather or other adverse climatological condition.
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15.2

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15.4

During the operations of loading, unloading and stock-piling, the pipe sections shall be handled in such a way so as to avoid dents, cuts, cracks and other damages especially at bevelled ends or damages to protective and / or concrete coating. Stacks shall consist of a limited number of layers such that the pressure exercised by the pipes own weight does not cause damage to coating. Stacking with more number of layers shall be agreed upon with the Company provided that each pipe section is separated by means of spacers suitably spaced so as to avoid stresses and compressed points of contact on the coated surfaces.

15.5

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STANDARD SPECIFICATION FOR REPAIR OF POLYETHYLENE COATING

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STANDARD SPECIFICATION FOR REPAIR OF POLYETHYLENE COATING

SPECIFICATION S-04-02-023

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STANDARD SPECIFICATION FOR REPAIR OF POLYETHYLENE COATING

SPECIFICATION S-04-02-023

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STANDARD SPECIFICATION FOR REPAIR OF POLYETHYLENE COATING

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1.0

SCOPE This specification covers the minimum requirements for materials and equipment, application procedure and inspection of repair of damaged Polyethylene coatings on steel pipes. The repair shall be carried out using repair patch made of radiation cross-linked polyolefin backing, coated on the inside with semi-crystalline thermoplastic adhesive and filler mastic. The repair patch shall have thermal indicators to ensure correct heat is being applied during application.

2.0 2.1

MATERIAL AND EQUIPMENT The repair material shall be as under: a) b) c) Repair Patch: radiation cross-linked polyolefin with semi-crystalline thermoplastic adhesive (PERP80 of make Covalence Raychem or equivalent). Filler Mastic: PERPFILLER of make Covalence Raychem or equivalent. PERP melt stick of make Covalence Raychem or equivalent

2.2 2.3 2.4 2.5

The repair material shall be certified by DIN to meet the requirements of EN12068 Stress Class CHT 80 The material shall not be older than their period of validity at the time of application by the Contractor. Deteriorated / decomposed materials shall not be used. Materials shall be stored in sheltered storages in the manufacturer's original packing away from direct sunlight and in accordance with manufacturer's instructions. Contractor shall supply all equipment and manpower required for a skillful application in the field in accordance with the specification.

3.0 APPLICATION PROCEDURE 3.1 The application procedure to be followed for holiday type of damage shall be in accordance with manufacturer's instruction and minimum requirement specified below whichever are the more stringent.

3.1 .1 Preparation

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Remove coating from damaged area with knife, scraper or power brush. Scrap off the damaged area and adjacent coating to remove oil, grease, rust, dirt and moisture. 3.1.2 Preheating Preheat the exposed bare metal surface to approx. 80" C and adjacent pipe coating to approx. 600 C with a torch moved back and forth over the surface. 3.1.3 Application of the Filler Plastic filler shall be cut to size and applied to all exposed metal surface. The mastic shall be heated and smoothed down with a paint scraper to cover all bare metal in a manner such that all entrapped air is removed. 3.1.4 Application of repair tape A patch shall be cut from the tape in a manner such that it extends 50 mm (2 inch) beyond the damaged area on all sides. The patch shall be positioned over the damaged area and heated until the temperature sensitive paint on the outside of the patch changes colour or dimples on the backing vanish. It shall be smoothed down to confirm with the contour of lap, and shall be freed of any air bubbles or wrinkles. 3.2 For cosmetic type of defects such as minor gouging, tearing, andlor scratches, which do not indicate holiday during holiday inspection, following procedure shall be adopted.

3.2.1 The defective area shall be roughened to remove loose polyethylene coating, oil, grease, dirt, etc. 3.2.2 This shall be followed by application of patch as detailed in clause 3.1.4 4.0 4.1 INSPECTION AND TEST A visual inspection shall be carried out for the following: Mastic extrusion on ends of the patch shall be examined There shall be no sign of punctures or pinholes or bend failure. The external appearance of the patch shall be smooth, free from dimples, air entrapment or void formation. The entire closure patch shall have changed colour uniformly.

4.2

Holiday lnsp