VISAKH MARKETING INSTALLATION RESITEMENT PROJECT BLACK OIL TERMINAL Doc No:254625-300-SP-PIP-012 Rev: A Page 1 of 11

TECHNICAL SUPPLY CONDITIONS FOR PIPES

Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059

Hindustan Petroleum Corporation Ltd Visakha Dispatch Station VR-ATP Area, Naval Base Post Visakhapatnam - 530 014 Andhra Pradesh

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List of Content 1 2 3 4 5 6 7 General Testing Specification IBR Pipes Hydrostatic Test Marking and Despatch Guarantee

Page No 4 4 4 9 9 10 11

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1 1.1

General
All items and their dimensions, tolerances, chemical compositions physical properties, heat treatment, hydrotest and other testing and marking requirements shall conform to the latest codes and standard specified in the material requisition (MR). Deviations(s), if any, shall be clearly highlighted in the offer. All piping components shall conform to the requirements of ASME B31.3 and relevant referenced Codes, Standards and specifications.

1.2

2 1.2.1

Testing
Test reports shall be supplied for all mandatory tests as per the applicable material specification. Test reports shall also be furnished for any supplementary tests as specified in the MR Material test certificates (physical property, chemical composition & heat treatment report) shall also be furnished for the items supplied.

1.2.2

Specification
This specification covers MS pipes (EW/SW) plain / bevel ended intended primarily for piping in storage unit for Petroleum product services, oil drain pipes and fire fighting facilities. The pipes for petroleum products shall conform to IS 1978 Yst 240: 1982. The pipes for oil drains shall conform to IS: 1239 (Part 1) Heavy : 2004. The pipes for steam service (IBR) shall conform to ASTM A106 Gr. B : 1999. The pipes for fire fighting facilities shall conform to ASTM A106 Gr. B / IS 1239 Heavy : 2004 / IS 3589 Fe410 : 2001. These pipes shall be Seamless, ERW (Electric Resistance welded) or SAW (Submerged Arc welded) pipes.

3.1

Acceptance of the materials shall be subject to inspection, approval and release by the inspection agency designated by HPCL. Inspection will be carried out as per the scope of inspection detailed in this specification and as per the relevant standard, for which all arrangements/ facilities shall be made by successful tenderer. Material and workmanship i. The pipes shall be new and the best of its kind. All pipes and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydro test and other testing and marking shall conform to the respective codes indicated against each category of pipes in the schedule of quantities. Deviations if any shall be clearly highlighted in the offer. ii. All the materials used shall be free from injurious defects and surface defects like scale, burns, fins, rusts, cracks and deformation etc. The inside surface shall be

3.2

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free from weld spatter, foreign matter or other obstruction. Reconditioning /repair of pipes by welding is not permitted. iii. Pipes shall be supplied in standard double random length. Pipes having OD more than 50mm shall be supplied with bevelled ends and less than 50mm with square ends. iv. Necessary test certificates shall be submitted to MMCI / HPCL for checking compliance to specified grade of materials. 3.3 Supplementary technical requirements / Inspection i. The Steel pipes shall be manufactured by any of the following process a. Electric welding. b. Helical seam submerged arc welding. c. Longitudinal seam arc welding.
ii. The Steel for the Pipe shall be made by one or more of the following processes: a. Open Hearth process b. Electric Arc Furnace process c. Basic Oxygen Furnace process iii. The chemical composition of steel shall be: ASME A106 Gr. B

C 0.3

Chemical Composition (Ladle Analysis), % Max Mn S P 1.06 0.035 0.035

Ni 0.4

IS 1239: 2004

C 0.2

Chemical Composition (Ladle Analysis), % Max Mn S P 1.30 0.040 0.040

IS: 1978-1982

C 0.22

Chemical Composition (Ladle Analysis), % Max Mn S P 0.9 0.05 0.04

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT BLACK OIL TERMINAL Doc No:254625-300-SP-PIP-012 IS 3589:2001 Fe 410 Rev: A Page 6 of 11

C 0.2
iv.

Chemical Composition (Ladle Analysis), % Max Mn S P 1.3 0.04 0.04

The weld seam of welded pipe shall be heat treated after welding to a minimum temperature of 540 deg. C so that no untempered martensite remains or otherwise processed in such a manner that no untempered martensite remains. All welded pipes should employ only automatic welding. Supplier must confirm the same. Supplier shall indicate specifically the technique of welding employed. The tenderer shall furnish in his offer, Quality Assurance Plan (QAP). For Inspection & Test Plan, refer to Indicative Inspection and Test Plan Doc. No. MMCI/STD/IND/ITP/M-001, R-00 The pipes shall not have any circumferential seam joint in a random length.

v. vi.

vii.

viii. Pipes in hydrocarbon services shall be of IS 1978 Yst 240 Electric Welded upto and including 14" & IS 1978 Yst 240 SAW with 100% Radiography for sizes 16" & above. ix. Tolerance on Length, Wall thickness & Diameter of Pipes shall be as follows.

ASME A106 Gr.B: Length: Nominal Length (m) Plain-End Pipe 12 Wall Thickness: Size, NB mm < 50 >50 and <500 >500 Diameter: Size, mm 80 > 80 Tolerance (w.r.t specified outside diameter) 0.4 mm 0.79 mm Type of Pipe Seamless Seamless Seamless Tolerance (%of specified wall thickness) Grade B or Lower 12.5 12.5 12.5 6.7 10.7 13.72 Minimum Length (m) Minimum avg. length for each order Item (m) Maximum Length (m)

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IS 1239:2004: Length: The Tolerance on Length of Pipes shall be within 150 mm of the specified Length. Random Lengths: For orders over 150m of any size of the tube, it shall be permissible to supply short random lengths from 2 to 4m provided that the number of such length does not exceed 5% of total number of lengths for sizes below 65 NB and 7.5% of total number of lengths for sizes 65 NB and above. Wall Thickness: Type of Pipe 1. Welded tubes Heavy IS: 1978 - 1982: Length: Type of Pipe 1. Threaded & Coupled Double random length 2. Plain end pipes Double random length Wall Thickness: Type of Pipe Seamless & welded pipes Welded pipes Pipe Size (OD, mm) 73 & smaller 88.9 101.6 to 457.2 508.0 & above Tolerance (%) +20.0, -12.5 +18.0, -12.5 +15.0, -12.5 +17.5, -10.0 Shortest length in entire shipment (m) 6.7 4.3 Minimum average length in entire shipment (m) 10.7 10.7 + Not limited - 10 % Tolerance (%of specified wall thickness)

Diameter: The outside Diameter tolerances shall be as follows Size of Pipe 48.3 mm OD and Less 60.3 and above Tolerance + 0.40 mm, -0.80 mm + 1%

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT BLACK OIL TERMINAL Doc No:254625-300-SP-PIP-012 IS 3589:2001 Length: Steel tubes shall be supplied in double random length of 7 m to 14 m. The permissible variations shall be +10 mm for length upto and including 6 m. Thickness : The thickness shall not apply to weld area. The maximum height of the weld bead on the internal surface of the pipe shall not exceed 60 % of the wall thickness. The tolerance of the specified wall thickness shall be as follows ERW Pipes SAW Pipes 10 % +20 % -12.5% Rev: A Page 8 of 11

Diameter: Tolerance on outer diameter shall be 0.75% for all dia pipes. x. xi. xii. No material shall be despatched before MMCI / HPCL confers the acceptance after the inspection. All pipes are to be inspected before application of varnish coating. The straightness shall be randomly checked for straightness and deviation from a straight line shall not exceed 0.2% of the length.

xiii. The pipes cleared by inspection agency shall be stamped with the identification mark of the inspection agency and marked in accordance with the code of manufacture. ASME A106 Gr.B Pipes The identification and marking method for A106 Gr. B pipes shall conform to ASTM A106 - 1999 IS 1239:2004 Tubes Each tube shall be marked with Manufacturers name/ Trademark, IS (Specification) Number, BIS Standard mark (if any) and Class. The different classes of tubes shall be distinguished by colour bands given hereunder. Heavy tubes Red IS: 1978-1982 The Pipes shall be marked with Manufacturers name/ Trademark, ISI monogram, Nominal Size (OD), Weight in Kg per m, Grade, Process of manufacture, Type of steel, Heat treatment, Hydrostatic test pressure (preceded by word TESTED) and Length.

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IS 3589 :2001 Each pipe shall be marked with Manufacturers name or trade mark, outside diameter and specified wall thickness and pipe designation. xiv. The inspection shall in no way relieve the supplier of his responsibility as per the contract and shall in no way be binding on MMCI / HPCL.

3.4

The pipes shall be cleaned and degreased before despatch. The pipes for petroleum products shall be provided with external protective varnish coating suitable for use in petroleum products. Rust preventive coating used on machined surfaces to be welded shall be easily removable and shall not be harmful to welding. Both the ends of the pipes supplied shall be protected with the following materials wherever necessary: Plain ends - plastic caps Bevelled ends wood, metal or plastic cover

3.5

Product catalogues giving details of manufacturing ranges and specifications shall be included in the offer.

4 4.1

IBR Pipes
Pipes under purview of IBR shall be accompanied with IBR certificate original in Form IIIA, duly approved and countersigned by IBR authority/local authority empowered by the Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. For carbon steel pipes under IBR the chemical composition shall conform to the following: Carbon (max.) Others (S, P, Mn) : : 0.25 % As prescribed in IBR regulation.

4.2

The chemical composition as indicated in this clause is not applicable for pipes other than IBR services.

5 5.1 5.2

Hydrostatic Test
All pipes shall be hydrostatically tested. The mill test pressure shall be as follows:

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT BLACK OIL TERMINAL Doc No:254625-300-SP-PIP-012 5.2.1 a) Seamless, E.R.W. & Spiral Welded: Carbon Steel Material Std. ASTM A106 Gr.B Test Pressure Std. ASTM A530 Rev: A Page 10 of 11

5.2.2

Carbon Steel Pipes to IS Standards: Material Std. IS 1239 IS 3589 IS 1978 Test Pressure Std. IS 1239 IS 3589 IS 1978

6 6.1

Marking and Despatch

All pipes shall be marked in accordance with the applicable codes, standards and specifications. In addition the purchase order number, the item code & special conditions like IBR shall also be marked. Pipes under IBR shall be painted in red strips longitudinally throughout the length for easy identification. 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 loose foreign materials of any kind. Pipes shall be protected from rust, corrosion and 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. Both ends of the pipes shall be protected with the following materials: Plain end Bevel end Thread end : : : Plastic cap Wood, Metal or Plastic cover Metal or Plastic threaded cap

6.2 6.3 6.4 6.5 6.6 6.7

6.8 6.9

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

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Guarantee
The supplies shall be fully guaranteed against any manufacturing defect/ poor workmanship/ inferior design or quality for a period of 12 months from the date of commissioning or 18 months from the date of last delivery whichever is earlier. Defects observed during this period shall be rectified or the defective items replaced by the tenderer at his cost.

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