GAIL Technical Spec.

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
(BIDDING DOCUMENT NO. - 8000000682)
S.
NO.
TITLE
REV.
SPEC.
No. of
Pages
JOB SPECIFICATION
1
2
3
4
5
6
7
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
0001-01-04-03-001
0001-01-05-02-001
19
68
0001-01-04-02-001
52
0
0
0001-01-04-02-001-WSC1
0001-01-04-02-001-WSC2
01
02
0001-01-04-02-002
06
0001-01-04-02-003
15
S-04-02-001
36
S-04-02-002
43
S-04-02-003
S-04-02-004
06
34
S-04-02-005
34
S-04-02-006
31
S-04-02-007
S-04-02-008
17
14
S-04-02-012
14
S-04-02-013
07
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)
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
S-04-02-014
07
S-04-02-015
10
S-04-02-016
12
S-04-02-017
17
S-04-02-018
S-04-02-019
S-04-02-020
08
S-04-02-021
15
S-04-02-022
15
S-04-02-023
06
S-04-02-024
08
S-04-02-025
15
S-04-02-026
11
S-04-02-027
15
S-04-02-028
43
S-04-02-029
22
S-04-02-030
05
S-04-02-031
09
S-04-02-032
11
S-04-02-033
17
S-04-02-034
32
S-04-02-035
10
Page 2 of 7
33
34
Spec. for Issue and

Reconciliation of Material
Spec. for Pipeline Information
Management system
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
S-04-02-036
09
S-04-02-037
06
0
0
S-05-02-001
S-05-02-002
09
17
S-05-02-003
07
S-05-02-004
05
S-05-02-005
03
S-05-02-006
03
S-05-06-001
04
S-05-02-011
16
S-05-02-012
16
S-05-02-013
10
S-05-02-014
49
S-14-02-001
07
S-04-01-001
02
S-04-01-002
01
0
0
S-04-01-003
S-04-01-004
01
01
S-04-01-005
02
S-04-01-006
01
0
0
S-04-01-007
S-04-01-008
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
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,
S-04-01-009
02
S-04-01-010
02
S-04-01-011
S-04-01-012
02
02
S-04-01-013
01
0
0
0
0
0
S-04-01-014
S-04-01-015
S-04-01-016
S-04-01-017
S-04-01-018
03
02
03
03
03
S-04-01-019
02
S-04-01-020
02
0
0
S-04-01-021
S-04-01-022
02
03
S-04-01-023
03
S-04-01-024
03
S-04-01-026
02
S-04-01-027
02
S-04-01-028
03
S-04-01-029
02
S-04-01-030
01
S-04-01-031
01
0
0
S-05-01-001
S-05-01-002
01
01
S-05-01-003
01
S-05-01-004
01
S-05-01-005
02
S-05-01-006
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 &
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
S-05-01-007
01
S-05-01-008
01
S-05-01-009
01
0
0
S-05-01-010
S-05-01-011
01
02
S-05-01-012
01
S-05-01-013
01
S-05-01-014
01
S-05-01-015
01
S-05-01-016
01
S-05-01-017
02
S-05-01-018
02
S-05-01-019
02
S-05-01-020
02
S-05-01-021
02
S-05-01-022
01
S-05-01-023
01
S-05-01-024
02
S-05-01-025
03
Page 5 of 7
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
24". type-L18 & L18A
Adjustable low support with
guide & cross guide for bare
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
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.
S-05-01-026
01
S-05-01-027
01
S-05-01-028
02
S-05-01-029
01
S-05-01-030
02
S-05-01-031
01
S-05-01-032
02
S-05-01-033
01
S-05-01-034
01
S-05-01-035
02
S-05-01-036
02
S-05-01-037
01
S-05-01-038
01
S-05-01-039
02
S-05-01-040
02
S-05-01-041
02
S-05-01-042
02
S-05-01-043
01
S-05-01-044
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
3
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#
8
Tee) - 18" X 12" , 600#
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
01
0001-00-10-01-6003
01
0001-00-10-01-6004
01
0001-00-10-01-6005
01
0001-00-10-01-6006
0001-00-10-01-6007
01
01
0001-00-10-01-6008
01
0001-00-10-01-6009
01
0001-00-10-01-6010
01
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
02
0
0
0
0001-01-04-04-BV-001
0001-01-04-04-BV-002
0001-01-04-04-BV-003
01
01
01
0001-01-04-04-PL/PR-001
01
0
0
0001-01-04-04-PSG-001
0001-01-04-04-IJ-001
01
01
0001-01-04-04-FLT-001
01
0001-01-04-04-FLT-002
01
0001-01-04-04-FLT-003
01
0001-01-04-04-QOEC-001
01
0001-01-04-04-GVA-001
04
0
0
0001-01-04-04-PV-001
0001-01-04-04-PV-002
01
01
0001-01-05-04-GV-001
03
Page 7 of 7
ENGINEERING DESIGN BASIS

(PIPELINE ENGINEERIG)
SPUR LINES OF CHAINSA JHAJJAR PIPELINE
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
0001-01-04-03-001
REV-0
Page 1 of 19
Copyright GAIL All rights reserved
TABLE OF CONTENTS
1.0
INTRODUCTION
2.0
SCOPE
3.0
DESIGN CODES AND STANDARDS
4.0
DESCRIPTION OF FACILITIES
5.0
PIPELINE ROUTE
6.0
DESIGN DATA
7.0
PIPELINE AND ASSOCIATED FACILITIES DESIGN
8.0
OTHER TECHNICAL REQUIREMENTS
ANNEXURE-A
LIST OF CODES AND STANDARDS
ENCLOSURES:
1. Schematic Arrangement for Pipeline Facilities Drawing no. 0001-00-03-01-5003.
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
0001-01-04-03-001
REV-0
Page 2 of 19
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)
Tap-off
point
at
Chainage 70.05 Km in
Chainsa-Jhajjar line
18 X 85.28
Spur Line
to Bhiwadi
Tap-off point at Chainage 12 X 9

31.6 Km in Sultanpur
Neemrana Line
Hayatpur to
Manesar
Tap-off
point
at
Hayatpur to
Gurgaon

61.14 Km in Chainsa-Jhajjar
line
10 X 5.4
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
GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-04-03-001
REV-0
Page 3 of 19
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
Inspection of Cross Country Pipelines-Onshore
ASME B 31.3
Chemical Plant & Petroleum Refinery Piping
API Std. 1102
Steel Pipeline Crossing Railways & Highways
API Std. 1104
Standard for Welding Pipelines and Related Facilities
ISO 13623
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
4.1.1 Despatch cum Receipt Station at Sultanpur and Neemrana

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
transition in the above ground section of pipeline. Filtering, metering and let down skid
with associated piping and Instruments.
GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-04-03-001
REV-0
Page 4 of 19
4.1.4 SV-2 , TOP and CGS at Khushkhera

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
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:
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
0001-01-04-03-001
REV-0
Page 5 of 19
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.
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
0001-01-04-03-001
REV-0
Page 6 of 19
All terminal facilities (equipment and associated piping) shall be designed for design
and operating conditions given in the process package.
7.0
PIPELINE AND ASSOCIATED FACILITIES DESIGN
7.1
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.
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Location
Class
Design Factor
All
Station Piping
Class 1
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
Class 2
7.3
Type of Facility
0.5
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
0.6
0.72
0.5
0.6
0.5
0.5
0.6
0.5
0.5
0.5
Class 3
All
0.5
Class 4
All
0.4
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
GRADE
Class - I Class - II
Class - III
Class
IV
18(457.2 mm)
6.5
7.9
9.3
11.7
12 (323.9 mm)
6.4
6.4
7.9
9.5
10 (273.1 mm)
X-70,
PSL-2
X-60,
PSL-2
X-60,
PSL-2
6.4
6.4
6.4
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.
Location
Minimum Cover
(m)
1.0
Industrial, commercial and residential

area
1.0
2.0
Rocky terrain
1.0
3.0
Minor water crossing/ canal/ drain/

nala/ waterways
1.5
4.0
HDD crossing of canals (below bed)
2.5
5.0
River crossings for which scour depth

is defined (below scour)
1.5
6.0
Other River crossings (Bank width >

50m) (Below Bed)
2.5 (For normal soil)

1.5 (For rocky strata)
7.0
Other River crossings (Bank width <

50m) (Below Bed)
1.5
8.0
Cased/uncased road crossing
1.2
9.0
Cased railway crossing
1.7
10.0
Drainage, ditches at roads/railway

crossings
1.2
11.0 Marshy land/Creek area
1.5
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
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
8.7.1 Water 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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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
8.8.1 Application of various types of valves shall be as follows:

Valve type
Typical application
Globe
Throttling
Ball
On/off, Isolation (on main line)
Plug
On/off, Isolation (in the terminals)
Check
Uni-directional flow
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)
Hot Formed
Cold Field
LR Bend
Bend Radius
Radius
R=27 D
R=6D
R=18 D
R=6D
R=18 D
R=6D
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
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
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
3. Flanges & Fittings

MSS-SP-44
Steel Pipeline Flanges
ANSI B16.5
Pipe Flanges and Flanged Fittings

Ring-joint Gaskets & Grooves for Steel Pipe
Flanges
Forgings, Carbon Steel for Piping Components
ANSI 16.20
ASTM A105
ASTM A193
API 601
Carbon & Alloy Steel Bolts & Studs for High

Temperature Service
Standard for Metallic Gaskets for Raised-Face Pipe
Flanges & Flanged Connections
ANSI B16.9
Factory Made Wrought Steel Butt Welding Fittings
ANSI B16.11
Forged Fittings, Socket Welded & Threaded
ANSI B16.26
ASTM A234
Butt Welding Ends
ASTM A694
MSS-SP-75
GAIL (INDIA) LTD
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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
SPECIFICATION
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Page 17 of 19
MSS-SP-97
Integrally Reinforced Forced Branch Outley Fittings

Socket Welding, Threaded and Butt Welding
Ends.
Pipe Bending Methods, Tolerances, Processes &
Material Requirements
PFI-ES-24
4. Testing & Welding
ANSI/AWS D1.1
API 1104
AWS A3.0
Structural Steel Welding

Standard for Welding Pipelines and Related
Facilities
Welding Terms and Definitions
AWS A5.1
AWS A5.5
Welding Electrodes
Specification for Low Alloy Steel Covered Arc
Welding Electrodes
ASTM E165
ASTM A370
Liquid Dye Penetrant Inspection of Pipeline Welds
ASTM E18
Standard Methods and Definitions for Mechanical

Testing of Steel Products.
Standard Hardness Test for Metals
ASTM E23
Standard for Impact Test for Metals
ASTM E84
ASTM E92
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
ASTM E110
ASTM E709
MSS-SP-53
MSS-SP-54
MSS-SP-55
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
Pictorial Surface Preparation Standards for Painting

Steel Surfaces
Solvent Cleaning
SSPC-SP-03
Power Tool Cleaning
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SSPC-SP-05
Joint Surface Preparation Standard: White Metal Blast

Cleaning
SSPC-SP10
Structural Steel Painting Council Joint Surface
NACE No.2
Preparation Standard - Near-White Metal Blast

Cleaning
SSPC-PA-02
Measurement of Dry Paint Thickness and Magnetic

Gauges
ASTM E12
ASTM-G6
Measurement of Pipeline Dry Film Coating Thickness

Abrasion Resistance of Pipeline Coating
ASTM G8
Cathodic Disbonding of Pipeline Coatings
NACE-RP-0274
High Voltage Electrical Inspection of Pipeline Coatings Prior to

Installation
IEC 454 2
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

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

A,B,C,D,E,F,G,H,I
ANNEXURE-1 LIST OF ATTACHMENTS

GAIL (INDIA) LTD
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1.0
SCOPE
1.1
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.
2.0
CODES AND STANDARDS
2.1
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
(ii)
ASME B31.3
Chemical Plant and Petroleum Refinery Piping
(iii)
OISD Standard 141
Design and Construction Requirements for Cross Country

Hydrocarbon Pipelines.
2.2
All codes, standards and specifications referred herein shall be the latest edition of such documents.
2.3
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.
2.4
In addition, GAIL specifications and standards for various piping and pipeline materials shall also
be applicable.
3.0
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.
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
PIPELINE
5.1
Line pipe material grade and wall thickness details are indicated in Table-I.
6.0
PIPES
6.1
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.
6.2
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.
6.3
All pipe threads shall conform to American Standard taper as per ASME B1.20.1 NPT, unless
otherwise specified.
6.4
For butt weld end, bevel shall be in accordance with API specification 5L or ASME B 16.25 as
applicable.
7.0
FITTINGS
7.1
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.
7.2
Threaded joints, if used, shall conform to American Standard taper as per ASME B1.20.1 NPT.
7.3
Dimensions of socket welded/ screwed fittings shall conform to ASME B 16.11. Swage shall be as
per BS 3799.
7.4
Dimensions of steel butt welded fittings shall be as per ASME B 16.9.
7.5
Bore of socket welded fittings shall suit outside diameter (OD) of pipe and its thickness.
7.6
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.
7.7
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.
7.8
Fittings thickness tolerances shall match pipe thickness tolerance.
8.0
BENDS
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 4 of 68
8.1
Unless otherwise specified for process piping, elbow of radius R

Minimum Bend Radius D = Specified Outside Diameter
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.
8.3
Miters shall not be used.
9.0
FLANGES
9.1
Pressure Temperature rating of flanges shall conform to B16.5/ MSS-SP44/ B16.47 Series A, as
applicable.
9.2
Dimensions of flanges shall be in accordance with B16.5/ MSS-5P44/ B16.47 Series A, as

applicable.
9.3
Neck of weld neck (WN) flanges shall suit pipe bore and thickness.
9.4
Bore of socket welded (SW) flanges shall suit pipe O.D. and its thickness.
9.5
Threads for screwed flanges, if used, shall conform to American Standard taper as per ASME B
1.20.1 NPT.
9.6
Sizes for blind flanges shall be indicated by nominal pipe size.
9.7
Unless specified otherwise in Piping Material Specification the flange face finish shall be as per
ASME B16.5.
9.8
Butt welding ends of WN flanges shall conform to ASME B 16.25.
9.9
Spectacle blind/ spacer & blinds shall be in accordance with ASME B16.48/ manufacturers
standard.
9.10
Two jack screws, 1800 apart shall be provided in spectacle blind or spacer & blind assemblies as per
GAIL standards.
10.0
GASKETS
10.1
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.
10.2
Spiral wound gasket shall be self-aligning type.
11.0
BOLTING & THREADS
11.1
Nuts for stud bolts shall be American Standard Hexagon Heavy Series and double chamfered.
11.2
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.
11.3
Threads for nuts shall be as per ASME B 1.1

Nuts for stud bolts dia to 1
1.5 D shall only be used.
UNC-2B

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
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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
UNC-2A
Stud bolts dia 1 % to 3
8UN-2A
11.5
Threads for threaded pipe, fitting, flanges and valve shall be in accordance with B1.20.1 taper
threads, unless specified otherwise.
11.6
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.
12.0
THREAD SEALANT
12.1
Threaded joints shall be made with 1 wide PTFE jointing tape.
13.0
VALVES
13.1
Valve ends shall be as per valve data sheets for various piping class.
13.2
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.
13.3
All buried valves shall be provided with stem extension, sealant, vent/drain and shall have butt
welded ends as per relevant specification/ data sheet.
13.4
Flange dimensions and face finish of flanged end valves shall conform to clause 9.0 of this
specification.
13.5
Butt welding ends of Butt Welded valves shall conform to ASME B 16.25.
13.6
Face to face and end to end dimensions shall conform to applicable standards.
13.7
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
Flanged/ Butt Welded end valves (2 and above)

Design STD. for Process Lines
Gate Valves
Globe Valves
Check Valves
:
:
:
API 6D
BS 1873
API 6D

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SPECIFICATION
0001-01-05-02-001
REV-0
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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
Hand wheel operated for size 12 NB.

Gear operated for size 14 NB.
For ANSI class 600
Hand wheel operated for size 10 NB.

Gear operated for size 12 NB
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
Wrench operated for size 4 NB.

Gear operated for size 6 NB.
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 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.

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 7 of 68
GAIL (INDIA) LTD

NEW DELHI
12
10
10
Bhiwadi/Chopanki TOP Bhiwadi Spur Line
Spur line Hayatpur - Manesar
Spur Line Hayatpur - Gurgaon
3.
3.
18
X 60, PSL-2
X 60, PSL-2
X 60, PSL-2
X 70, PSL-2
SEAMLESS ,EW
SEAMLESS ,EW
SEAMLESS ,EW
LSAW, HSAW,
SEAMLESS, EW
6.4
6.4
6.4
6.5
METHOD OF
MANUFACTURE
Sultanpur Nimrana Pipe line
MATERIAL
(API 5L)
Class
I
TPIPE
DIA
(INCH)
LINE PIPE
SECTION
2.
1.
Sl.
No.
6.4
6.4
6.4
7.9
Class
II
6.4
6.4
7.9
9.3
Class
III
W.T. (mm)
6.4
7.8
9.5
11.7
Class IV
TABLE -1
SPECIFICATION
0001-01-05-02-001
REV-0
Page 8 of 68
TABLE 2
Design Condition
Pressure
Temp.
(Kg/cm2 )
(0 C)
99.93
65
Class
Service
D1A
Hydrocarbon
Gas
B1A
Hydrocarbon
Gas
49.0
65
1.5
A1A
Hydrocarbon
Gas
19
65
1.5
A3A
Utilities
10.5
65
1.5
J2A
Potable Water
10.5
65
A93A
Fire Water
18.9
65
1.5
C.A. (mm)
Pipe
Material
Design
Code
1.5
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
ASME B
31.8 /
OISD
141
ASME B
31.8 /
OISD
141/ 226
ASME B
31.8 /
OISD
141 / 226
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.

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 9 of 68
ANNEXURE A
(A1A - CLASS 150#)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 10 of 68
PIPING CLASS
A1A, 150 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
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.
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
ALL BUTT WELDS
100%
MPI
SOCKET WELDS
100%
3.
PIPING DESIGN AS PER ASME B 31.8 & OISD 226.
4.
CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.
5.
6.
7.
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
DESCRIPTION
FLANGED TO BE KEPT MINIMUM
1.5 & BELOW
SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
REFER GAIL STD.S-05-01-003
ON LINES 2.0
AS PER P&ID OR 0.75 REFER STD.S-05-01-004
ON LINES 1.5
REFER GAIL STD S-05-01-003
ON LINES 2.0
TEMP. CONN
1.5
PRESS. CONN
0.75
FLANGED, INSTALLATION AS PER

GAIL STD
S-05-01-005.
SW NIPPLE WITH GATE VALVE TO SPEC AS PER
DRAINS
VENTS
STD.S-05-01-006

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 11 of 68
W
S
W
S
T
T
T
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
5.000
W
S
4.000
T
S
3.500
T
S
3.000
T
T
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)
10.00
8.000
6.000
2.500
1.000
T
T
T
2.000
0.750
T
T
1.500
T
T
T
1.250
T
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
RUN PIPE (SIZES IN INCH) A1A

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0001-01-05-02-001
REV-0
Page 12 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Lower
Size
(Inch)
Upper
Size
(Inch)
Sch./
Thk
Dim.
STD
Material
Description
PIPE
00.500
00.750
S160
B 36.10
ASTMA 106 GR.B
PE, SEAMLESS
PIPE
01.000
01.500
XS
B 36.10
ASTMA 106 GR.B
PE, SEAMLESS
PIPE
02.000
02.000
XS
B 36.10
ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE
03.000
03.000
STD
B 36.10
ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE
04.000
04.000
STD
B 36.10
ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE
06.000
06.000
STD
B 36.10
ASTMA106 GR.B
(CHARPY)
BE, SEAMLESS
PIPE
8.000
14.000
6.4
API 5L
API 5L GR.B PSL2
BE, SEAMLESS
PIPE
16.000
18.000
6.4
API 5L
API 5L GR.B PSL2
BE, SAW
PIPE
20.000
20.000
7.1
API 5L
API 5L GR.B PSL2
BE, SAW
NIPPLE
00.500
00.750
B 36.10
ASTMA 106 GR.B
PBE, SEAMLESS
NIPPLE
01.000
01.500
B 36.10
ASTMA 106 GR.B
PBE, SEAMLESS
FLNG.WN
00.500
01.500
B-16.5
ASTM A 105
150, RF/125AARH
FLNG.WN
02.000
24.000
B-16.5
ASTM A 105 (CHARPY)
150, RF/125AARH
FLNG.BLIND
00.500
01.500
B-16.5
ASTM A 105
150, RF/125AARH
PLNG.BLIND
02.000
24.000
B-16.5
ASTM A105 (CHARPY}
150, RF/125AARH
FLNG.FIG8
00.500
01.500
B-16.48
ASTM A 105
150, RF/125AARH
Item Type
Pipe Group (A1A)
Flange Group (A1A)

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SPECIFICATION
0001-01-05-02-001
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FLNG.FIG8
02.000
08.000
B-16.48
ASTM A105 (CHARPY)
150, RF/125AARH
SPCR &BLIND
10.000
24.000
B-16.48
ASTM A105 (CHARPY)
150, RF/125AARH
ELBOW.90
00.500
0..750
B-16.11
ASTM A 105
SW, 6000
ELBOW.90
01.000
1.500
B-16.11
ASTM A 105
SW, 3000
ELBOW.90
02.000
24.000
B-16.9
ASTM A 234,GR. WPB

(CHARPY)
BW, 1.5D
ELBOW.45
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
ELBOW.45
01.000
01.500
B-16.11
ASTMA 105
SW, 3000
ELBOW.45
02.000
24.000
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW, 1.5D
T.EQUAL
00.500
00.750
B 16.11
ASTM A 105
SW, 6000
T.EQUAL
01.000
01.500
B 16.11
ASTM A 105
SW, 3000
T.EQUAL
02.000
24.000
B-16.9
ASTM A234,GR.WPB
(CHARPY)
BW
T.RED
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
T.RED
01.000
01.500
B-16.11
ASTMA 105
SW, 3000
T.RED
02.000
24.000
M, M
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
REDUC.CONC
02.000
24.000
M,M
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
REDUC.ECC
02.000
24.000
M,M
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
SWAGE.CONC
00.500
03.000
M,M
BS-3799
ASTM A 105 (CHARPY)
PBE
SWAGE.ECC
00.500
03.000
M,M
BS-3799
ASTM A 105 (CHARPY)
PBE
CAP
00.500
00.750
B-16.11
ASTMA 105
SCRF, 6000
CAP
01.000
01.500
B-16.11
ASTMA 105
SCRF, 3000
CAP
02.000
24.000
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
CPLNG.FULL
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.FULL
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG-HALF
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.HALF
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
Fitting Group (A1A)

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 14 of 68
CPLNG.LH
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.LH
01.000
01.500
B-16.11
ASTM A 105
SW,3000
CPLNG.RED
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.RED
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
SOCKOLET
00.500
0.750
MSSSP97
ASTM A 105
SW, 6000
SOCKOLET
01.000
01.500
MSSSP97
ASTM A 105
SW, 3000
WELDOLET
02.000
10.000
MSSSP97
ASTMA 105 (CHARPY)
BW
VLV.GATE
00.500
01.500
API-602
BODY-ASTM A
105, TRIM-STELLITED,
STEM13%CR. STEEL
SW,800, 3000,B16.11
VLV.GLOBE
00.500
01.500
BS-5352
BODY-ASTM A
105,TRIM-STELLITED,
STEM13%CR STEEL
SW,800, 3000,B16.11
VLV.CHECK
00.500
01.500
BS-5352
BODY-ASTMA
105,TRIM-STELLITED
SW,800, 3000, B16.11
00.500
24.000
B18.2
BOLT: 193 GR.B7,NUT:

A194 GR. 2H
24.000
B16.20ANSI B
16.5
SP,WND, SS316+CAF
Olet Group (A1A)
M,
XXS
Valves Group (A1A)
Bolt Group (A1A)

BOLT.STUD
Gasket Group (A1A)

GASKET
00.500

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SPIRAL, 150
SPECIFICATION
0001-01-05-02-001
REV-0
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ANNEXURE B
(A3A - CLASS 150#)

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 16 of 68
PIPING CLASS
A3A, 150 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
NON IBR
SERVICE : NON CORROSIVE UTILITIES (ABOVE GROUND) COOLING WATER, INERT GAS,
INSTRUMENT AIR, CONDENSATE
NOTES
1.
2.
NDT REQUIREMENT AS PER GAIL STANDARD S-05-02-012
3. FOR VALVES REFER VALVE DATA SHEET

SPECIAL NOTES
ITEM
MAINTENANCE
JOINTS
PIPE JOINTS
SIZE
ALL
DESCRIPTION
FLANGED TO BE KEPT MINIMUM
1.5 & BELOW
SW COUPLING 3000 #
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75 S-05-01-004
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75, S-05-01-004
TEMP. CONN
1.5
FLANGED, INSTALLATION AS PER GAIL STD.

S-05-01-005
PRESS. CONN
0.75
SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD.
DRAINS
VENTS
S-05-01-006

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0001-01-05-02-001
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Page 17 of 68
H
H
H
H
H
H
H
H
H
H
H
H
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
6.000
T
T
T
5.000
P
H
4.000
P
H
3.500
P
H
3.000
T
T
2.500
2.000
1.000
1.500
T
T
T
1.250
T
T
0.750
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
(A3A)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 18 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
T
W
I
X
L
Lower
Size
(Inch)
Upper
Size
(Inch)
Sch./
Thk
Dim.
STD
PIPE
00.500
1.50
HVY
PIPE
02.000
06.000
NIPPLE
00.500
Item Type
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Material
Description
IS-1239I
IS-1239 (BLACK)
PE, C. WELDED
HVY
IS-1239I
IS-1239 (BLACK)
PE, C. WELDED
01.50
HVY
IS-1239I
IS-1239 (BLACK)
PE, C. WELDED
B-16.5
ASTM A 105
150,
RF/125AARH
Pipe Group (A3A)
Flange Group (A3A)

FLNG.SW
00.500
01.500
FLNG.SO
02.000
06.000
B-16.5
ASTM A 105 (CHARPY)
150,
RF/125AARH
FLNG.BLIND
00.500
01.500
B-16.5
ASTM A 105
150,
RF/125AARH
FLNG.BLIND
2.00
6.00
B-16.5
ASTM A105 (CHARPY}
FLNG.FIG8
00.500
01.500
B-16.48
ASTM A 105
150,
RF/125AARH
150,
RF/125AARH
FLNG.FIG8
02.000
06.000
B-16.5
ASTM A105 (CHARPY)
150,
RF/125AARH
B-16.11
ASTM A 105
SW,3000
B-16.9
ASTM A 234 GR. WPB

(CHARPY)
BW, 1.5D
B-16.11
ASTM A 105
SW, 3000
B-16.9
ASTM A 234 GR. WPB

(CHARPY)
BW, 1.5D
B 16.11
ASTM A 105
SW, 3000
Fitting Group (A3A)

ELBOW.90
00.500
01.500
ELBOW.90
02.00
06.00
ELBOW.45
00.500
01.50
ELBOW.45
02.000
06.000
T.EQUAL
00.500
01.50
STD
STD

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
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T.EQUAL
02.00
06.00
T.RED
00.500
01.500
T.RED
02.000
06.00
REDUC.CONC
02.000
REDUC.ECC
STD
B 16.11
ASTM A 234 GR. WPB

(CHARPY)
BW
B-16.11
ASTM A 105
SW, 3000
STD
B-16.9
ASTM A 234 GR. WPB

(CHARPY)
BW
06.000
STD,STD
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
02.000
06.000
STD,STD
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
SWAGE.CONC
00.500
03.000
STD,STD
BS-3799
ASTM A 105 (CHARPY)
PBE
SWAGE.ECC
00.500
03.000
STD,STD
BS-3799
ASTM A 105 (CHARPY)
PBE
CAP
00.500
01.50
B-16.11
ASTMA 105
SCRF, 3000
CAP
02.000
06.00
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
CPLNG.FULL
00.500
01.50
B-16.11
ASTM A 105
SW, 3000
CPLNG-HALF
00.500
01.50
B-16.11
ASTM A 105
SW, 3000
CPLNG.LH
00.500
01.50
B-16.11
ASTM A 105
SW, 3000
CPLNG.RED
00.500
01.50
B-16.11
ASTM A 105
SW, 3000
UNION
0.50
01.500
BS-3799
ASTM A 105
SW, 3000
STD
Valves Group (A3A)

VLV.GATE
00.250
01.500
API-602
BODY-ASTM A
105, TRIM-STELLITED,
STEM13%CR. STEEL
SW,800, 3000,B16.11
VLV.GATE
02.00
24.00
API-600
BODY-ASTM A
216, WCB, TRIMSTELLITED, STEM13%CR.
STEEL
FLGD, 150, B
16.5,
RF/125AARH
VLV.GLOBE
00.25
01.500
BS-5352
BODY-ASTM A
105,TRIM-STELLITED,
STEM13%CR STEEL
SW,800, 3000,B16.11
VLV.GLOBE
02.00
16.00
BS-1873
BODY-ASTM A
216, WCB, TRIMSTELLITED, STEM13%CR.
STEEL
FLGD, 150, B
16.5,
RF/125AARH
VLV.CHECK
00.250
01.500
BS-5352
BODY-ASTMA
105,TRIM-STELLITED
SW,800, 3000, B16.11
VLV.CHECK
02.00
24.00
BS 1868
BODY-ASTM A 216, GR.

WCB, TRIM 13% CR.
SREEEL
FLGD, 150, B
16.5,
RF/125AARH

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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
FLGD, 150, , B
16.5,
RF/125AARH
VLV.BTRFLY
03.500
24.00
BS-5155
BODY-ASTM A 216 GR.,

WCB, TRIM- 13% CR.
STEEL
WAFL, 150, B16.5

WAF/125AARH
00.500
6.000
B18.2
BOLT: A 307, GR. B, NUT:

A 563 GR.B
6.000
B16.21ANSI B
16.5
IS-2712- GR.-W/3
RING, 150, 2 MM
Bolt Group (A3A)

BOLT.STUD
Gasket Group (A3A)

GASKET
00.500
TRAP/ STRAINER GROUP (A3A)

TRP
00.500
1.50
MANFS
STD
B:A105, T:13%CR, S:SS304
FLGD,
THRMDNMC,
150, RF/125AARH
TRP
01.500
6.000
MANUF
STD
B:A285GR.C; INT: SS304
CONETYPE, 150,
FF/125 AARH
TRP
00.500
1.500
MANUF
STD
B:A105; INT: SS304
SW, Y-TYPE, 800
TRP
02.00
6.000
MANUF
STD
B:A234GR. WPB; INT:

SS304
BW, T - TYPE

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 21 of 68
ANNEXURE C
(B1A - CLASS 300#)

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 22 of 68
PIPING CLASS
(B1A), 300 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
NON IBR
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
2. NDT OF WELDS SHALL BE AS FOLLOWS:
RADIOGRAPHY
ALL BUTT WELDS
100%
MPI
SOCKET WELDS
100%
3.
PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226
4.
FLANGES OF SIZE 22 SHALL BE AS PER MSS-SP-44.
5.
CHARPY V-NOTCH TEST & HARDNESS TEST SHALL BE CONDUCTED FOR PIPE, FITTINGS AND
FLANGES.
6.

7.
FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.
SPECIAL NOTES
ITEM
SIZE
DESCRIPTION
MAINTENANCE JOINTS
ALL
FLANGED, TO BE KEPT MINIMUM
PIPE JOINTS
1.5 & BELOW
SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75; GAIL STD. S-05-01-004
ON LINES 1.5
REFER GAIL STD. S-05-01-003
ON LINES 2.0
AS PER P&ID OR 0.75. S-05-01-004
TEMP. CONN
1.5
FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005
PRESS. CONN
0.75
SW NIPPLE WITH GATE VALVE TO SPEC AS PER STD. S05-01-006
DRAINS
VENTS

GAIL (INDIA) LTD
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0001-01-05-02-001
REV-0
Page 23 of 68
72
70
70
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
30
28
28
26
26
24
24
22
22
20
20
18
16
14
12
18
16
14
12
10
8.0
6.0
10
8.0
5.0
T
3.5
4.0
3.5
3.0
2.5
3.0
2.5
2.0
1.5
2.0
1.5
0.75
T T
0.5
6.000
8.000
10.000
12.000
14.000
16.000
18.000
20.000
5.000
4.000
3.500
3.000
2.500
2.000
1.500
1.0
1.250
T
T
1.000
1.25
0.500
0.750
1.25
0.5
6.0
5.0
4.0
0.75
72
1.0
(B1A)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 24 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Lower
Size
(Inch)
Upper
Size
(Inch)
Sch./
Thk
Dim. STD
Material
Description
PIPE
00.500
00.750
S160
B 36.10
ASTMA 106 GR.B
PE, SEAMLESS
PIPE
01.000
01.500
XS
B 36.10
ASTMA 106 GR.B
PE, SEAMLESS
PIPE
02.000
02.000
XS
B 36.10
ASTMA106 GR.B (CHARPY)
BE, SEAMLESS
PIPE
03.000
03.000
STD
B 36.10
BE, SEAMLESS
PIPE
04.000
06.000
STD
B 36.10
BE, SEAMLESS
PIPE
08.000
08.000
7.9
API 5L
API 5L GR.B PSL2
BE, SEAMLESS
PIPE
10.000
10.000
9.3
API 5L
API 5L GR.B PSL2
BE, SEAMLESS
PIPE
12.000
12.000
10.3
API 5L
API 5L GR.B PSL2
BE, SEAMLESS
PIPE
14.000
14.000
11.1
API 5L
API 5L GR.B PSL2
BE, SEAMLESS
PIPE
16.000
16.000
12.7
API 5L
API 5L GR.B PSL2
BE, SAW
PIPE
18.000
18.000
14.3
API 5L
API 5L GR.B PSL2
BE, SAW
PIPE
20.000
20.000
15.9
API 5L
API 5L GR.B PSL2
BE, SAW
NIPPLE
00.500
00.750
B 36.10
ASTM A 106 GR.B
PBE, SEAMLESS
NIPPLE
01.000
01.500
B 36.10
ASTM A 106 GR.B
PBE, SEAMLESS
Flange Group (B1A)

FLNG.SW
00.500
01.500
B-16.5
ASTM A 105
300,
RF/125AARH
FLNG.WN
02.000
16.000
B-16.5
ASTM A 105 (CHARPY)
300,
RF/125AARH
FLNG.WN
18.000
20.000
B-16.5
ASTM A 105 (CHARPY)
300,
RF/125AARH
FLNG.BLIND
00.500
01.500
B-16.5
ASTM A 105
300,
RF/125AARH
FLNG.BLIND
02.000
20.000
B-16.5
ASTM A105 (CHARPY}
FLNG.FIG8
00.500
01.500
B-16.48
ASTM A 105
300,
RF/125AARH
300,
RF/125AARH
Item Type
Pipe Group (B1A)

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 25 of 68
FLNG.FIG8
02.000
08.000
B-16.48
ASTM A105 (CHARPY)
SPCR &BLIND
10.000
20.000
B-16.48
ASTM A105 (CHARPY)
Fitting Group(B1A)
ELBOW.90
00.500
0..750
B-16.11
ASTM A 105
SW, 6000
ELBOW.90
01.000
1.500
B-16.11
ASTM A 105
SW, 3000
ELBOW.90
02.000
16.000
B-16.9
ASTM A 234,GR. WPB

CHARPY)
BW, 1.5D
ELBOW.90
18.000
20.000
B- 16.9
ASTM A 234,GR. WPB

CHARPY)
BW, 1.5D
ELBOW.45
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
ELBOW.45
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
ELBOW.45
02.000
16.000
B-16.9
ASTM A234, GR. WPB

CHARPY)
BW, 1.5D
ELBOW.45
18.000
20.000
B 16.9
ASTM A234, GR. WPB

CHARPY)
BW, 1.5D
T.EQUAL
00.500
00.750
B 16.11
ASTM A 105
SW, 6000
T.EQUAL
01.000
01.500
B 16.11
ASTM A 105
SW, 3000
T.EQUAL
02.000
16.000
B-16.9
ASTM A234,GR.WPB
(CHARPY)
BW
T.EQUAL
18.000
20.000
B 16.9
ASTM A234,GR.WPB
(CHARPY)
BW
T.RED
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
T.RED
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
T.RED
02.000
16.000
M, M
B-16.9
ASTM A234,GR.
WPB(CHARPY)
BW
T.RED
18.000
20.000
M, M
B 16.9
ASTM A234,GR.
WPB(CHARPY)
BW
REDUC.CONC
02.000
16.000
M,M
B-16.9
ASTM A234,GR.
WPB(CHARPY)
BW
REDUC.CONC
18.000
26.000
M,M
B-16.9
ASTM A234,GR.
WPB(CHARPY)
BW
REDUC.ECC
02.000
16.000
M,M
B-16.9
ASTM A234,GR.
WPB(CHARPY)
BW
REDUC.ECC
18.000
20.000
M,M
B 16.9
ASTM A234,GR.
WPB(CHARPY)
BW
SWAGE.CONC
00.500
03.000
M,M
BS-3799
ASTM A 105 (CHARPY)
PBE
SWAGE.ECC
00.500
03.000
M,M
BS-3799
ASTM A 105 (CHARPY)
PBE

GAIL (INDIA) LTD
NEW DELHI
300,
RF/125AARH
300,
RF/125AARH
SPECIFICATION
0001-01-05-02-001
REV-0
Page 26 of 68
CAP
00.500
00.750
B-16.11
ASTM A 105
SCRF, 6000
CAP
01.000
01.500
B-16.11
ASTM A 105
SCRF, 3000
CAP
02.000
16.000
B-16.9
ASTM A234,GR. WPB

(CHARPY)
BW
CAP
18.000
20.000
B 16.9
ASTM A234,GR. WPB

(CHARPY)
BW
PLUG
00.500
00.750
B 16.11
ASTM A 105
SCRM, 6000
PLUG
01.000
01.500
B 16.11
ASTM A 105
SCRM, 3000
CPLNG.FULL
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.FULL
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG-HALF
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.HALF
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG.LH
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.LH
01.000
01.500
B-16.11
ASTM A 105
SW,3000
CPLNG.RED
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.RED
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
O let group(B1A)
SOCKOLET
00.500
0.750
MSS-SP97
ASTM A 105
SW, 6000
SOCKOLET
01.000
01.500
MSS-SP97
ASTM A 105
SW, 3000
WELDOLET
02.000
10.000
MSS-SP97
ASTMA 105 (CHARPY)
BW
M,
XXS
Valves Group (B1A)

VLV.GATE
00.500
01.500
API-602
BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR.

STEEL
SW,800, 3000,B16.11
VLV.GATE
02.000
20.000
API-6D
BODY-ASTM A 216 GR. WCB

TRIM-STELLITED, STEM 13%
CR. STEEL
FLGD, 300, B16.5, RF/ 125

AARH
VLV.GLOBE
00.500
01.500
BS-5352
BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR

STEEL
SW,800, 3000,B16.11
VLV.GLOBE
02.000
20.000
BS-1873

CR. STEEL
FLGD, 300, B16.5, RF/ 125

AARH
VLV.CHECK
00.500
01.500
BS-5352
BODY-ASTMA
105,TRIM-STELLITED
SW,800, 3000, B16.11
VLV.CHECK
2.000
20.000
API -6D

FLGD, 300, B16.5, RF/ 125

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 27 of 68
CR. STEEL
AARH
VLV.BALL
00.500
01.500
BS-5351
BODY-ASTM A 105,TRIMSEAT RPTFE
FLGD, 300, B16.5, RF/ 125

AARH
VLV.BALL
02.000
20.000
API-6D
BODY-ASTM A 216 GR. WCC/

A234 GR WPC, TRIM-SEAT
AISI 4140+0.003 ENP/ AISI 410
FLGD, 300, B16.5, RF/ 125

AARH
VLV.BALL
02.000
02.000
API-6D

A234 GR WPC, TRIM-SEAT
AISI 4140+0.003 ENP/ AISI 410
BW, 300, B16.25, RF/ 125

AARH
VLV.PLUG
00.500
01.500
BS-5353
BODY-ASTM A 105, PLUG-A

105 +0.003 ENP
SW,800 3000, B16.11
VLV.PLUG
02.000
20.000
API-6D

PLUG-A 216 GR. WCB+0.003
ENP
FLGD, 300, B16.5, RF/ 125

AARH
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
SP,WND, SS316+CAF
SPIRAL, 300
GASKET
20.000
B16.20ANSIB
16.5
SP,WND, SS316+CAF
SPIRAL, 300
26.000

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 28 of 68
ANNEXURE D

(D1A - CLASS 600#)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 29 of 68
PIPING CLASS
D1A, 600 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
NON IBR
SERVICE - REGASIFIED LNG (R-LNG) / Natural Gas

NOTES
1.
2.
WALL THICKNESS OF LINEPIPE (MAIN PIPELINE) USED SHALL BE AS PER TABLE 1

ENCLOSED.
3.
BALL VALVE TO BE USED IN MAIN LINE SHALL HAVE BUTT WELDED ENDS.
4.
MAINLINE WELDING AND NDT REQUIREMENTS OF WELDS SHALL AS PER SPECIFICATION

0001-01-04-02-001.
5.
BARRED TEE SHALL BE WELDED TYPE FOR USE IN MAINLINE ONLY. MATERIAL SHALL BE
AS PER ATTACHED TABLE-3 FOR PIPELINE SPECIALITY ITEMS.
6.
LR BEND,IJ,L/R, PIG SIG. SHALL BE FOR USE IN MAINLINE ONLY, MATERIAL AS PER TABLE-3.
7.
NDT OF WELDS EXCLUDING MAINLINE SHALL BE AS FOLLOWS:

RADIOGRAPHY
MPI
:
:
ALL BUTT WELDS

SOCKET WELDS
100%
100%
ALL OTHER REQUIREMENT SHALL BE AS PER S-05-02-012

8.
PIPING DESIGN AS PER ASME B 31.8 & OISD 141
9.
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
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

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0001-01-05-02-001
REV-0
Page 30 of 68
14. SPECIAL NOTES - D1A

ITEM
SIZE
DESCRIPTION
MAINTENANCE JOINTS
PIPE JOINTS
ALL
1.5 & BELOW

SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75. REFER STD. S-05-01-003
TEMP. CONN
1.5
PRESS. CONN
0.75
FLANGED, INSTALLATION AS PER GAIL STD.

S-05-01-005
S-05-01-006
DRAINS
VENTS

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 31 of 68
70
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
T 30
28
28
26
24
22
20
18
16
14
12
10
T 26
T 24
T 22
T 20
T 18
T 16
T 14
T 12
T 10
W 8.0
W 6.0
W 4.0
W 3.0
W 2.0
8.0
6.0
5.0
5.0
4.0
3.5
3.5
3.0
2.5
2.5
2.0
1.5
1.5
1.0
0.75
T T
0.5
2.000
6.000
8.000
10.000
12.000
14.000
16.000
18.000
20.000
22.000
24.000
26.000
30.000
28.000
5.000
4.000
3.500
3.000
2.500
0.75
1.250
1.0
0.750
T
T
1.500
1.25
1.000
1.25
0.5
72
70
0.500
72
RUN PIPE (SIZES IN INCH) D1A

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 32 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Lower
Size
(Inch)
Upper
Size
(Inch)
Sch./
Thk
Dim. STD
Material
Description
PIPE
00.500
00.750
S160
B 36.10
ASTM A 106 GR.B
PE, SEAMLESS
PIPE
01.000
01.500
XS
B 36.10
ASTM A 106 GR.B
PE, SEAMLESS
PIPE
02.000
02.000
XS
B 36.10
ASTM A106 GR.B (CHARPY)
BE, SEAMLESS
PIPE
03.000
06.000
XS
B 36.10
ASTM A106 GR.B (CHARPY)
BE, SEAMLESS
PIPE
08.000
08.000
14.3
API 5L
API 5L GR.B PSL2
BE, SEAMLESS
PIPE
10.000
10.000
12.7
API 5L
API 5L X-52 PSL2
BE, SEAMLESS
PIPE
12.000
12.000
14.3
API 5L
API 5L X-52 PSL2
BE, SEAMLESS
PIPE
14.000
14.000
14.3
API 5L
API 5L X - 52 PSL2
BE, SEAMLESS
PIPE
16.000
16.000
17.5
API 5L
API 5L GR.X-52 PSL2
BE, SAW
PIPE
18.000
18.000
19.1
API 5L
API 5L GR.X-52 PSL2
BE, SAW
PIPE
20.000
20.000
20.6
API 5L
API 5L GR.X-52 PSL2
BE, SAW
PIPE
24.000
24.000
19.1
API 5L
API 5L GR.X-52 PSL2
BE, SAW
PIPE
28.00
28.00
22.2
API 5L
API 5L GR.X-52 PSL2
BE, SAW
PIPE
30.00
30.00
API 5L
API 5L GR.X-52 PSL2
BE, SAW
NIPPLE
00.500
00.750
B 36.10
ASTM A 106 GR.B
PBE,SEAMLESS
NIPPLE
01.000
01.500
B 36.10
ASTM A 106 GR.B
PBE,
SEAMLESS
Item Type
Pipe Group (D1A)
Flange Group (D1A)

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

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0001-01-05-02-001
REV-0
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FLNG.BLIND
00.500
01.500
B-16.5
ASTM A 105
600,
RF/125AARH
FLNG.BLIND
02.000
24.000
B-16.5
ASTM A105 (CHARPY}
FLNG.BLIND
26.000
30.000
B16.47A
ASTM A105 (CHARPY}
FLNG.FIG8
00.500
01.500
B-16.48
ASTM A 105
600,
RF/125AARH
600,
RF/125AARH
600,
RF/125AARH
FLNG.FIG8
02.000
08.000
B-16.48
ASTM A105 (CHARPY)
SPCR &BLIND
10.000
24.000
B-16.48
ASTM A105 (CHARPY)
SPCR &BLIND
26.000
30.000
MNFS
STD
ASTM A516 GR.70 (CHARPY)
600,
RF/125AARH
600,
RF/125AARH
600,
RF/125AARH
Fitting Group (D1A)

ELBOW.90
00.500
0..750
B-16.11
ASTM A 105
SW, 6000
ELBOW.90
01.000
1.500
B-16.11
ASTM A 105
SW, 3000
ELBOW.90
02.000
8.000
B-16.9
ASTM A 234,GR. WPB (CHARPY)
BW, 1.5D
ELBOW.90
10.000
30.000
MSS-SP75
MSS-SP75 GR.WPHY-52
BW, 1.5D
ELBOW.45
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
ELBOW.45
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
ELBOW.45
02.000
8.000
B-16.9
ASTM A234, GR. WPB (CHARPY)
BW, 1.5D
ELBOW.45
10.000
30.000
MSS-SP75
MSS-SP75 GR.WPHY-52
BW, 1.5D
PIPE BEND
18.000
30.000
MSS-SP75
MSS-SP75 GR.WPHY-52
BW, 1.5D
T.EQUAL
00.500
00.750
B 16.11
ASTM A 105
SW, 6000
T.EQUAL
01.000
01.500
B 16.11
ASTM A 105
SW, 3000
T.EQUAL
02.000
8.000
B-16.9
ASTM A234,GR.WPB (CHARPY)
BW
T.EQUAL
10.000
30.000
MSS-SP75
MSS-SP75 GR.WPHY-52
BW
T.RED
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
T.RED
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
T.RED
02.000
8.000
M, M
B-16.9
ASTM A234,GR. WPB(CHARPY)
BW
T.RED
10.000
30.000
M, M
MSS-SP75
MSS-SP75 GR.WPHY-52
BW
REDUC.CONC
02.000
8.000
M,M
B-16.9
BW
REDUC.CONC
10.000
30.000
M,M
MSS-SP75
MSS-SP75 GR.WPHY-52
BW
REDUC.ECC
02.000
8.000
M,M
B-16.9
BW
REDUC.ECC
10.000
30.000
M,M
MSS-SP75
MSS-SP75 GR.WPHY-52
BW

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0001-01-05-02-001
REV-0
Page 34 of 68
SWAGE.CONC
00.500
03.000
M,M
BS-3799
ASTM A 105 (CHARPY)
PBE
SWAGE.ECC
00.500
03.000
M,M
BS-3799
ASTM A 105 (CHARPY)
PBE
CAP
00.500
00.750
B-16.11
ASTM A 105
SCRF, 6000
CAP
01.000
01.500
B-16.11
ASTM A 105
SCRF, 3000
CAP
02.000
8.000
B-16.9
ASTM A234,GR. WPB (CHARPY)
BW
CAP
10.000
30.000
MSS-SP75
MSS-SP75 GR.WPHY-52
BW
PLUG
00.500
00.750
B 16.11
ASTM A 105
SCRM, 6000
PLUG
01.000
01.500
B 16.11
ASTM A 105
SCRM, 3000
CPLNG.FULL
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.FULL
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG-HALF
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.HALF
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG.LH
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.LH
01.000
01.500
B-16.11
ASTM A 105
SW,3000
CPLNG.RED
00.500
00.750
B-16.11
ASTM A 105
SW, 6000
CPLNG.RED
01.000
01.500
B-16.11
ASTM A 105
SW, 3000
SOCKOLET
00.500
0.750
MSS-SP97
ASTM A 105
SW, 6000
SOCKOLET
01.000
01.500
MSS-SP97
ASTM A 105
SW, 3000
WELDOLET
02.000
16.000
M,
XXS
MSS-SP97
ASTMA 105 (CHARPY)
BW
WELDOLET
18.000
20.000
M,
M
MSS-SP97
ASTMA 694 GR. F-52 (CHARPY)
BW
O let group (D1A)
Valves Group (D1A)

VLV.GATE
00.500
01.500
API-602
BODY-ASTM A 105, TRIMSTELLITED, STEM13%CR.

STEEL
SW,800, 3000,B16.11
VLV.GLOBE
00.500
01.500
BS-5352
BODY-ASTM A 105,TRIMSTELLITED, STEM13%CR STEEL
SW,800, 3000,B16.11
VLV.CHECK
00.500
01.500
BS-5352
BODY-ASTMA
105,TRIM-STELLITED
SW,800, 3000, B16.11
VLV.BALL
00.500
01.500
BS-5351
BODY-ASTM A 105,TRIM-SEAT
RPTFE
FLGD, 600, B16.5, RF/ 125

AARH

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

A234 GR WPC, TRIM-SEAT AISI
4140+0.003 ENP/ AISI 410
FLGD, 600, B16.5, RF/ 125

AARH
VLV.BALL
26.000
30.000
API-6D

4140+0.003 ENP/ AISI 410
BW, 600, B16.25, RF/ 125

AARH
VLV.BALL
02.000
30.000
API-6D

4140+0.003 ENP/ AISI 410
BW, 600, B16.25, RF/ 125

AARH
VLV.PLUG
00.500
01.500
BS-5353
BODY-ASTM A 105, PLUG-A 105

+0.003 ENP
SW, 800 3000, B16.11
VLV.PLUG
02.000
24.000
API-6D

ENP
FLGD, 600, B16.5, RF/ 125

AARH
VLV.PLUG
02.000
24.000
API-6D

ENP
BW, 600, B-16.5,

RF/ 125 AARH
00.500
30.000
B18.2
BOLT: 193 GR.B7,NUT: A194 GR.

2H
Bolt Group(D1A)
BOLT.STUD
Gasket Group(D1A)
GASKET
00.500
24.000
B16.20ANSI
B16.5
SP,WND, SS316+CAF
SPIRAL, 600
GASKET
26.000
30.000
B16.20ANSI
B16.47A
SP,WND, SS316+CAF
SPIRAL, 600

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 36 of 68
ANNEXURE E

(A4A - CLASS 150#)

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 37 of 68
PIPING CLASS
A4A, 150 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
LOW TEMPERATURE SERVICE
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
RADIOGRAPHY
ALL BUTT WELDS
100%
MPI
SOCKET WELDS
100%
3.
4.
IMPACT TESTING IS REQUIRED
5.

6.
7.
FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC.
S-05-01-007
SPECIAL NOTES
ITEM
SIZE
DESCRIPTION
MAINTENANCE JOINTS
ALL
PIPE JOINTS
1.5 & BELOW
SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75 REFER STD. S-05-01-004
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75.REFER STD. S-05-01-003
TEMP. CONN
1.5
PRESS. CONN
0.75

S-05-01-006
DRAINS
VENTS

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 38 of 68
70
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
30
28
28
26
26
24
24
22
22
20
20
18
18
16
16
14
14
12
10
8.0
12
10
8.0
6.0
5.0
T
3.5
4.0
3.5
3.0
2.5
3.0
2.5
2.0
1.5
2.0
1.5
0.75
T T
0.5
8.000
10.000
12.000
14.000
5.000
4.000
3.500
3.000
2.500
2.000
1.500
1.0
1.250
T
T
6.000
1.25
1.000
1.25
0.5
6.0
5.0
4.0
0.75
72
70
0.500
0.750
72
1.0

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 39 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
Upper
Lower
Size
Size
(Inch)
(Inch)
Item Type
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Sch./
Thk
Dim. STD
Material
Description
Pipe Group (A4A)

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

FLNG. WN
00.500
14.000
B-16.5
ASTM A 350 GR. LF2
150, RF/125 AARH
FLNG.BLIND
00.500
14.000
B-16.5
ASTM A 350 GR. LF2
150, RF/125 AARH
FLNG.FIG.8
00.500
8.000
ASMEB16.48
ASTM A 350 GR. LF2
150, FF/125 AARH
SPCR &BLIND
10.000
14.000
ASMEB16.48
ASTM A 350 GR. LF2
150, FF/125 AARH
Fitting Group (A4A)

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

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 40 of 68
T.RED
02.000
14.000
M, M
B-16.9
ASTM A 420 GR.WPL6
BW
REDUC.CONC
02.000
14.000
M,M
B-16.9
ASTM A 420 GR.WPL6
BW
REDUC.ECC
02.000
14.000
M,M
B-16.9
ASTM A 420 GR.WPL6
BW
SWAGE.CONC
00.500
03.000
M,M
BS-3799
ASTM A 350 GR.LF2
PBE
SWAGE.ECC
00.500
03.000
M,M
BS-3799
ASTM A 350 GR.LF2
PBE
CAP
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SCRF, 6000
CAP
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SCRF, 3000
CAP
02.000
14.000
B-16.9
ASTM A 420 GR.WPL6
BW
CPLNG.FULL
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.FULL
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
CPLNG-HALF
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.HALF
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
CPLNG.LH
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.LH
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW,3000
CPLNG.RED
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.RED
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
O let group(A4A)
SOCKOLET
00.500
0.750
MSS-SP97
ASTM A 350 GR.LF2
SW, 6000
SOCKOLET
01.000
01.500
MSS-SP97
ASTM A 350 GR.LF2
SW, 3000
WELDOLET
02.000
10.000
MSS-SP97
ASTM A 350 GR.LF2
BW
M,
XXS
Valves Group (A4A)

VLV.GATE
00.500
01.500
API-602
BODY-ASTM A 350 GR. LF2,

TRIM-STELLITED, STEM SS-304
SW,800, 3000,B16.11
VLV.GLOBE
00.500
01.500
BS-5352
BODY-ASTM A 350 GR.LF2,

TRIM-STELLITED, STEM SS304
SW,800, 3000,B16.11
VLV.CHECK
00.500
01.500
BS-5352
BODY-ASTM A 350, GR.LF2,

TRIM-STELLITED
SW,800, 3000, B16.11
00.500
14.000
B18.2
BOLT: A 320 GR.L7, NUT:A194

GR.4
Bolt Group (A4A)

BOLT.STUD

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 41 of 68
Gasket Group (A4A)

GASKET
00.500
14.000
B16.20ANSI
B16.5
SP,WND, SS316+CAF

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
SPIRAL, 150
REV-0
Page 42 of 68
ANNEXURE F

(B4A - CLASS 300#)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 43 of 68
PIPING CLASS
B4A, 300 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
SERVICE
UPTO -45 DEG C.HYDROCARBONS, XYLENE, PROPYLENE, LPG, METHANOL, NH3, GAS FLARE ETC.
NOTES
RADIOGRAPHY
ALL BUTT WELDS
100%
MPI
SOCKET WELDS
100%
3.
4.
5.

6.
7.
S-05-01-007
SPECIAL NOTES
ITEM
SIZE
DESCRIPTION
MAINTENANCE JOINTS
ALL
PIPE JOINTS
1.5 & BELOW
SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75. S-05-01-004
TEMP. CONN
1.5
PRESS. CONN
0.75

S-05-01-006
DRAINS
VENTS

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 44 of 68
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
30
28
28
26
26
24
24
22
22
20
20
18
18
16
16
14
14
12
10
8.0
12
10
8.0
6.0
5.0
4.0
3.5
T
2.5
3.0
2.5
2.0
1.5
2.0
1.5
0.75
T T
0.5
6.000
8.000
10.000
12.000
14.000
5.000
4.000
3.500
3.000
2.500
2.000
1.500
1.0
1.250
T
T
1.000
1.25
0.500
0.750
1.25
0.5
4.0
3.5
3.0
0.75
6.0
5.0
1.0
RUN PIPE (SIZES IN INCH) B4A

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 45 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
Lower Upper
Sch./
Size
Size
Thk
(Inch) (Inch)
Item Type
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Dim.
STD
Material
Description
Pipe Group (B4A)

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

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

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

GAIL (INDIA) LTD
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SPECIFICATION
0001-01-05-02-001
REV-0
Page 46 of 68
T.RED
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
T.RED
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
T.RED
02.000
14.000
M,
M
B-16.9
ASTM A 420 GR.WPL6
BW
REDUC.CONC
02.000
14.000
M,M
B-16.9
ASTM A 420 GR.WPL6
BW
REDUC.ECC
02.000
14.000
M,M
B-16.9
ASTM A 420 GR.WPL6
BW
SWAGE.CONC
00.500
03.000
M,M
BS3799
ASTM A 350 GR.LF2
PBE
SWAGE.ECC
00.500
03.000
M,M
BS3799
ASTM A 350 GR.LF2
PBE
CAP
02.000
14.000
B-16.9
ASTM A 420 GR.WPL6
BW
CPLNG.FULL
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.FULL
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
CPLNG-HALF
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.HALF
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
CPLNG.LH
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.LH
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW,3000
CPLNG.RED
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.RED
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
O let group (B4A)

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

VLV.GATE
00.500
01.500
API602

SW,800, 3000,B-16.11
VLV.GATE
00.200
24.000
API600
BODY-ASTM A 352 GR. LCB,

FLGD,300, B16.5,
RF/125AARH
VLV.GLOBE
00.500
01.500
BS5352

TRIM-STELLITED, STEM
SS304
SW,800, 3000,B-16.11

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SPECIFICATION
0001-01-05-02-001
REV-0
Page 47 of 68
VLV.GLOBE
02.000
12.000
BS1873
BODY-ASTM A 352 GR.LCB,

SS304
FLGD,300, B16.5, RF/125AARH
VLV.CHECK
00.500
1.500
BS5352

TRIM-STELLITED
SW,800, 3000, B-16.11
VLV.CHECK
02.000
24.000
BS1868
BODY-ASTM A 352, GR.LCB,

TRIM-STELLITED
VLV.BALL
00.500
16.000
BS5351
BODY-ASTM A 352,
GR.LCB/ ASTM A350,
GR.LF2, TRIM-BODY SEATRPTFE
00.500
14.000
B18.2
BOLT: A 320 GR.L7,

NUT:A194 GR.4
14.000
B16.20ANSI
B16.5
SP,WND, SS316+CAF
SPIRAL, 300
GAIL
STD.
B:A516GR.70(NORM);
CONETYPE,300,FF/125AARH
Bolt Group (B4A)

BOLT.STUD
Gasket Group (B4A)

GASKET
00.500
Trap/ Strainer Group (B4A)

STRNR.TEMP
01.500
14.00
INT:SS304
STRNR.TEMP
00.500
1.500
GAIL
STD.
B:A350GR.LF2
SW, Y-TYPE, 800
(NORM);INT:SS304
STRNR.TEMP
02.000
14.000
GAIL
STD.
B:A420GR.WPL6;
BW, T-TYPE
INTR:SS304

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 48 of 68
ANNEXURE G

(D4A - CLASS 600#)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 49 of 68
PIPING CLASS
D4A, 600 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
SERVICE
UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC.
NOTES
RADIOGRAPHY
ALL BUTT WELDS
100%
MPI
SOCKET WELDS
100%
3.
4.
5.

6.
7.
S-05-01-007
SPECIAL NOTES
ITEM
SIZE
DESCRIPTION
MAINTENANCE JOINTS
ALL
PIPE JOINTS
1.5 & BELOW
SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75, REFER STD. S-05-01-004
ON LINES 1.5
ON LINES 2.0
TEMP. CONN
1.5
PRESS. CONN
0.75

S-05-01-006
DRAINS
VENTS

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 50 of 68
70
70
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
30
28
28
26
26
24
24
22
22
20
20
18
16
14
12
10
8.0
6.0
18
16
14
12
10
8.0
6.0
5.0
5.0
4.0
3.5
3.0
2.5
1.5
2.0
1.5
0.75
T T
0.5
6.000
8.000
10.000
12.000
14.000
16.000
1.0
18.000
5.000
4.000
3.500
3.000
2.500
2.000
1.500
1.0
1.250
T
T
1.000
1.25
0.500
0.750
1.25
0.5
3.0
2.5
2.0
0.75
4.0
3.5
RUN PIPE (SIZES IN INCH) D4A

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 51 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
Lower Upper
Sch./
Size
Size
Thk
(Inch) (Inch)
Item Type
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Dim.
STD
Material
Description
Pipe Group (D4A)

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

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

ELBOW.90
00.500
0.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
ELBOW.90
01.000
1.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 52 of 68
ELBOW.90
02.000
14.000
B-16.9
ASTM A 420 GR.WPL6
BW, 1.5D
ELBOW.90
16.000
18.000
B-16.9
ASTM A 420 GR.WPL6-W
BW, 1.5D
ELBOW.45
00.500
0.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
ELBOW.45
01.000
1.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
ELBOW.45
02.000
14.000
B-16.9
ASTM A 420 GR.WPL6
BW, 1.5D
ELBOW.45
16.000
18.000
B-16.9
BW, 1.5D
T.EQUAL
00.500
00.750
B 16.11
ASTM A 350 GR.LF2
SW, 6000
T.EQUAL
01.000
01.500
B 16.11
ASTM A 350 GR.LF2
SW, 3000
T.EQUAL
02.000
14.000
B-16.9
ASTM A 420 GR.WPL6
BW
T.EQUAL
16.000
18.000
B-16.9
BW
T.RED
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
T.RED
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
T.RED
02.000
14.000
M,
M
B-16.9
ASTM A 420 GR.WPL6
BW
T.RED
16.000
18.000
M,
M
B-16.9
BW
SWAGE.CONC
00.500
03.000
M,M
BS3799
ASTM A 350 GR.LF2
PBE
SWAGE.ECC
00.500
03.000
M,M
BS3799
ASTM A 350 GR.LF2
PBE
CAP
00.500
0.750
B-16.11
ASTM A 350, GR.LF2
SCRF, 6000
CAP
01.000
1.500
B-16.11
ASTM A 350 GR.LF2
SCRF, 3000
CAP
02.000
18.000
B-16.9
ASTM A 420 GR.WPL6
BW
PLUG
00.500
0.750
B-16.11
ASTM A 350, GR.LF2
SCRM, 6000
PLUG
01.000
1.500
B-16.11
ASTM A 350 GR.LF2
SCRM, 3000
CPLNG.FULL
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.FULL
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
CPLNG-HALF
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.HALF
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
CPLNG.LH
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000
CPLNG.LH
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW,3000
CPLNG.RED
00.500
00.750
B-16.11
ASTM A 350 GR.LF2
SW, 6000

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 53 of 68
CPLNG.RED
01.000
01.500
B-16.11
ASTM A 350 GR.LF2
SW, 3000
O let group (D4A)

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

VLV.GATE
00.500
01.500
API602

SW,800, 3000,B-16.11
VLV.GLOBE
00.500
01.500
BS5352

SS304
SW,800, 3000,B-16.11
VLV.CHECK
00.500
1.500
BS5352

TRIM-STELLITED
SW,800, 3000, B-16.11
VLV.PLUG
00.500
1.500
BS5353

PLUG:A350 GR.LF2+0.003
ENP
SW,800, 3000, B-16.11
VLV.PLUG
02.000
18.000
API-6D
BODY-ASTM A 352,
GR.LCB/ ASTM A350,
GR.LF2, TRIM-SS 304/ SS316
BW, 600, B-16.25
18.000
B18.2
BOLT: A 320 GR.L7,

NUT:A194 GR.4
18.000
B16.20ANSI
B16.5
SP,WND, SS316+CAF
Bolt Group (D4A)

BOLT.STUD
00.500
Gasket Group (D4A)

GASKET
00.500

GAIL (INDIA) LTD
NEW DELHI
SPIRAL, 600
SPECIFICATION
0001-01-05-02-001
REV-0
Page 54 of 68
ANNEXURE H

(A93A - CLASS 150#)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 55 of 68
PIPING CLASS
A93A, 150 #
BASE MATERIAL
CARBON STEEL
CORROSION ALLOWANCE
1.5 MM
SPECIAL REQUIREMENT
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.
BUTTERFLY VALVE SHALL BE LUGGED WAFER TYPE UP TO 24 AND DOUBLE FLANGED

BODY FOR SIZES BEYOND 24.
5.
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.
6.
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.
SPECIAL NOTES
ITEM
SIZE
DESCRIPTION
MAINTENANCE JOINTS
ALL
PIPE JOINTS
1.5 & BELOW
SW COUPLING
2.0 & ABOVE
BUTT WELDED
ON LINES 1.5
ON LINES 2.0
ON LINES 1.5
ON LINES 2.0
AS PER P&ID OR 0.75REFER STD. S-05-01-003.
TEMP. CONN
1.5
PRESS. CONN
0.75

S-05-01-006
DRAINS
VENTS

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 56 of 68
70
70
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
30
28
28
26
26
24
24
22
22
20
20
18
18
16
16
14
12
14
12
10
8.0
6.0
10
8.0
6.0
5.0
5.0
4.0
3.5
3.5
3.0
2.5
3.0
2.5
2.0
1.5
2.0
1.5
1.0
0.75
0.5
10.000
12.000
14.000
5.000
4.000
3.500
3.000
2.500
2.000
1.500
1.250
0.500
0.750
T
T
1.000
1.0
0.75
8.000
1.25
6.000
1.25
0.5
4.0

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 57 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
Lower Upper
Sch./
Size
Size
Thk
(Inch) (Inch)
Item Type
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Dim.
STD
Material
Description
Pipe Group (A93A)

PIPE
00.500
01.500
HVY
IS-1239-I
IS-1239 (BLACK)
PE, C. WELDED
PIPE
02.000
06.000
HVY
IS-1239-I
IS-1239 (BLACK)
BE, C. WELDED
PIPE
08.000
12.000
6.0
IS-3589
IS-3589 GR.410
BE, WELDED
PIPE
14.000
14.000
8.0
IS-3589
IS-3589 GR.410
BE, SEAMLESS
NIPPLE
00.500
01.500
HVY
IS-1239 (BLACK)
PBE, C. WELDED
B-16.5
ASTM A 105
150, RF/125 AARH
Flange Group(A93A)
FLNG. SW
00.500
1.50
FLNG. SO
02.000
14.000
B-16.5
ASTM A 105
150, RF/125 AARH
FLNG.BLIND
00.500
14.000
B-16.5
ASTM A 105
150, RF/125 AARH
FLNG.FIG.8
00.500
8.000
ASMEB16.48
ASTM A 105
150, FF/125 AARH
SPCR &BLIND
10.000
14.000
ASMEB16.48
ASTM A 105
150, FF/125 AARH
B-16.11
ASTM A 105
SW, 3000
Fitting Group(A93A)
ELBOW.90
00.500
1.500
ELBOW.90
02.000
6.000
STD
B-16.9
ASTM A 234 GR.WPB
BW, 1.5D
ELBOW.90
8.000
14.000
B-16.9
ASTM A 234 GR.WPB-W
BW, 1.5D
ELBOW.45
00.500
1.500
B-16.11
ASTM A 105
SW, 3000
ELBOW.45
02.000
6.000
STD
B-16.9
ASTM A 234 GR.WPB
BW, 1.5D
ELBOW.45
08.000
14.000
B-16.9
ASTM A 234 GR.WPB-W
BW, 1.5D
T.EQUAL
00.500
01.500
B 16.11
ASTM A 105
SW, 3000
T.EQUAL
02.000
6.000
B 16.9
ASTM A 234 GR.WPB
BW
STD

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 58 of 68
T.EQUAL
08.000
14.000
T.RED
00.500
01.500
T.RED
02.000
06.000
T.RED
08.000
REDUC.CONC
B-16.9
ASTM A 234 GR.WPB-W
BW
B-16.11
ASTM A 105
SW, 3000
STD.,STD
B-16.9
ASTM A 234 GR.WPB
BW
14.000
M, M
B-16.9
ASTM A 234 GR.WPB-W
BW
02.000
06.000
STD.,STD
B-16.9
ASTM A 234 GR.WPB
BW
REDUC.CONC
08.000
14.000
M, M
B-16.9
ASTM A 234 GR.WPB-W
BW
REDUC.ECC
02.000
06.000
STD.,STD
B-16.9
ASTM A 234 GR.WPB
BW
REDUC.ECC
08.000
14.000
M, M
B-16.9
ASTM A 234 GR.WPB-W
BW
SWAGE.CONC
00.500
03.000
M,M
BS-3799
ASTM A 105
PBE
SWAGE.ECC
00.500
03.000
M,M
BS-3799
ASTM A 105
PBE
CAP
00.500
1.500
B-16.11
ASTM A 105
SCRF, 3000
CAP
02.000
6.000
STD
B-16.9
ASTM A 234 GR.WPB
BW
CAP
08.000
14.000
B-16.9
ASTM A 234 GR.WPB
BW
CPLNG.FULL
00.500
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG.HALF
00.500
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG.LH
00.500
01.500
B-16.11
ASTM A 105
SW, 3000
CPLNG.RED
00.500
01.500
B-16.11
ASTM A 105
SW, 3000
UNION
00.500
01.500
BS-3799
ASTM A 105
SW, 3000
Valves Group(A93A)
VLV.GATE
00.500
01.500
API-602
BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR.

STEEL
SW,800, 3000,B-16.11
VLV.GATE
02.000
24.000
API-600
BODY-ASTM A 216
GR.WCB, TRIM-13% CR.
STEEL
FLGD, 150, B16.5,

RF/125AARH
VLV.GLOBE
00.500
01.500
BS-5352
BODY-ASTM A 105, TRIMSTELLITED, STEM 13%CR.

STEEL
SW,800, 3000,B-16.11
VLV.GLOBE
02.000
16.000
BS-1873
BODY-ASTM A 216
GR.WCB, TRIM-13% CR.
STEEL
FLGD, 150, B16.5,

RF/125AARH
VLV.CHECK
00.500
1.500
BS-5352
BODY-ASTM A 105, TRIMSTELLITED,
SW,800, 3000,B-16.11
VLV.BTRFLY
02.000
24.000
BS-5155
BODY-ASTM A 216 GR. WCB,

TRIM-13% CR.STEEL,
WAFL, 150, B16.5,

WAF/ 125AARH

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 59 of 68
Bolt Group(A93A)
BOLT.STUD
00.500
14.000
B18.2
BOLT: A 193 GR.B7,

NUT:A194 GR.2H
14.000
B16.21ANSI
B16.5
IS-2712-GR. W/3
RING, 150, 2MM
MNFSTD
B:A105;INT;SS304
SW, Y-TYPE, 800
Gasket Group(A93A)
GASKET
00.500
Trap/ Strainer Group(A93A)

STRNR.PERM
00.500
1.500
STRNR.PERM
02.000
6.000
GAIL
STD
B:A234GR.WPB;INT:SS304
BW, T-TYPE
STRNR.PERM
08.000
14.000
GAIL
STD
B:A234GR.WPBW;INT:SS304
BW, T-TYPE

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 60 of 68
ANNEXURE I

(J2A - CLASS 150#)

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 61 of 68
PIPING CLASS
J2A, 150 #
BASE MATERIAL
CS (Galv.)
CORROSION ALLOWANCE
0 MM
SPECIAL REQUIREMENT
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
SIZE
DESCRIPTION
MAINTENANCE JOINTS
1.5 & BELOW
UNIONS (SCRF) TO BE KEPT MINIMUM
2 & ABOVE
FLANGED (SCREWED) TO BE KEPT MINIMUM
PIPE JOINTS
UP TO 6
SCREWED COUPLING
DRAINS
ON LINES 1.5
ON LINES 2.0
ON LINES 1.5
ON LINES 2.0
TEMP. CONN
1.5
PRESS. CONN
0.75
SCREWED NIPPLE WITH VALVE TO SPEC. S-05-01-006
VENTS

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 62 of 68
70
70
68
68
66
66
64
64
62
62
60
60
58
58
56
56
54
54
52
52
50
50
48
48
46
46
44
44
42
42
40
40
38
38
36
36
34
34
32
32
30
30
28
28
26
26
24
24
22
22
20
20
18
18
16
16
14
14
12
12
10
10
8.0
8.0
6.0
5.0
4.0
3.5
4.0
3.5
3.0
2.5
3.0
2.5
2.0
1.5
1.25
2.0
1.5
1.25
1.0
6.000
0.5
5.000
0.75
4.000
T
3.500
T
3.000
T
2.500
2.000
1.500
1.250
T
T
1.000
0.75
0.750
0.500
0.500
1.0
0.5
6.0
5.0
RUN PIPE (SIZES IN INCH) J2A

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 63 of 68
CODE
DESCRIPTION
F
H
P
R
S
SADDLE FUSED JT
H.COUPLING
PIPE TO PIPE
REINFORCED
SOCKOLETS
Lower Upper
Sch./
Size
Size
Thk
(Inch) (Inch)
Item Type
T
W
I
X
L
TEES
WELDOLETS
INSTRUMENT TEE
REFER NOTES
SWEEPOLET
Dim.
STD
Material
Description
IS-1239-I
IS-1239 (GALV)
SCRM, WELDED
Pipe Group (J2A)

PIPE
00.500
06.000
HVY
Flange Group(J2A)
FLNG. SCRD
00.500
06.00
B-16.5
ASTM A 105 (GALV.)
150, FF/125 AARH
FLNG.BLIND
00.500
06.000
B-16.5
ASTM A 105 (GALV.)
150, FF/125 AARH
FLNG.FIG.8
00.500
06.000
ASMEB16.48
ASTM A 105 (GALV.)
150, FF/125 AARH
Fitting Group(J2A)
ELBOW.90
00.500
1.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
ELBOW.90
02.000
6.000
IS-1239-II
IS-1239 (PART-II) (GALV.)
SCRF, NA
ELBOW.45
00.500
1.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
ELBOW.45
02.000
6.000
IS-1239-II
SCRF, NA
T.EQUAL
00.500
01.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
T.EQUAL
02.000
6.000
IS-1239-II
SCRF, NA
T.RED
00.500
01.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
T.RED
02.000
6.000
IS-1239-II
SCRF, NA
SWAGE.CONC
00.500
03.000
M,M
BS-3799
ASTM A 105 (GALV.)
TBE
SWAGE.ECC
00.500
03.000
M,M
BS-3799
ASTM A 105 (GALV.)
TBE
CAP
00.500
1.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
CAP
02.000
6.000
IS-1239-II
SCRF, NA
CPLNG.FULL
00.500
01.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
CPLNG.HALF
00.500
01.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
CPLNG.LH
00.500
01.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000
CPLNG.RED
00.500
01.500
B-16.11
ASTM A 105 (GALV.)
SCRF, 3000

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 64 of 68
UNION
00.500
06.000
IS-1239-II
SCRF, NA
Valves Group(J2A)
VLV.GATE
00.500
01.500
IS:778
CL.2
BODY-IS 318 GR.2 LEADED

TIN BRONZE, TRIM-IS320
ALLOY HT2
SCRF, CL.2, 3000, B1.20.1
VLV.GATE
02.000
6.000
IS:780
BODY-IS 210,GR.FG 200,

TRIM-IS 320 ALLOY HT2
FLGD, PN 1.6, B
16.1,FF/125AARH
VLV.GLOBE
00.500
01.500
IS:778
CL.2

ALLOY HT2
SCRF, CL.2, 3000, B1.20.1
VLV.CHECK
00.500
1.500
IS:778
CL.2

ALLOY HT2
SCRF, CL.2, 3000, B1.20.1
VLV.CHECK
02.000
6.000
IS:5312
(PT-1)
BODY-IS 210 GR.FG 200,

TRIM-IS 320 ALLOY HT2
FLGD, PN1.6, B-16.1,

FF/125AARH
00.500
6.000
B18.2
BOLT: A 307, GR.B (GALV),

NUT:A563 GR.B (GALV)
6.000
B16.21ANSI
B16.5
BUTYL RUBBER
Bolt Group(J2A)
BOLT.M/C
Gasket Group(J2A)
GASKET
00.500

GAIL (INDIA) LTD
NEW DELHI
FULL FACE, 150, 2MM
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
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT
NO.
S-05-01-001
REV
.
0
S-05-01-002
S-05-01-003
S-05-01-004
S-05-01-005
S-05-01-006
S-05-01-007
0
0
0
S-05-01-008
S-05-01-009
S-04-02-001
S-04-02-002
S-04-02-015
0
0
0
S-04-02-016
S-04-02-019
0
0
S-04-02-013
S-04-02-014
S-04-02-013
S-05-02-002
S-05-02-001
S-05-02-003
0
0
0
S-05-02-004
S-05-02-005
S-05-02-006
S-14-06-001
S-05-02-014
S-05-02-011
0
0
0
0
0
S-05-02-013
S-05-02-012
SPECIFICATION
0001-01-05-02-001
REV-0
Page 66 of 68
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
0
0
0
S-14-02-001
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
7
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
RE
V.
0
0001-01-04-04-PSG-001
0001-01-04-04-QOEC-001
0
0
0001-01-04-04-IJ-001
0001-01-04-04-FLT-001
0
0
0001-01-04-04-FLT-002
0001-01-04-04-FLT-003
0001-01-05-04-BV-001
0001-01-04-04-GVA-001
0
0
0001-01-04-04-PV -001
0001-01-05-04-GV-001
0
0

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 67 of 68
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
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)
FLOW TEES (BARRED TEES)
INSULATING JOINTS
SCRAPPER LAUNCHER &

RECIEVER
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)
PIG SIGNALLER
Body: ASTM A 105 (CHARPY)

Internals: SS316
For Mainline Items, corrosion allowance shall be 0.0 mm except for scraper traps where 3
mm corrosion allowance shall be taken.

GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION
0001-01-05-02-001
REV-0
Page 68 of 68
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
CONTENTS
1.0
SCOPE
2.0
APPLICABLE CODES AND STANDARDS
3.0
BASE MATERIAL
4.0
WELDING CONSUMABLES
5.0
EQUIPMENT AND ACCESSORIES
6.0
WELDING PROCESSES
7.0
BEVEL CLEANING AND BEVEL INSPECTION
8.0
ALIGNMENT AND SPACING
9.0
WEATHER CONDITIONS
10.0
WELDING
11.0
HEAT TREATMENT
12.0
INSPECTION AND TESTING
13.0
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

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SPECIFICATION
0001-01-04-02-001
REV- 0
Page 2 of 52
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)
Code for Gas Transmission and Distribution Piping Systems, ANSI B31.8.
b)
Standard for Welding of Pipelines and Related Facilities, API 1104.
c)
Specification for Welding Electrodes and Filler Materials, ASME Sec. II Part C
d)
Non-Destructive Examination, ASME Sec. V.
e)
3.0
Welding and Brazing Qualifications, ASME Sec. IX
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.
GAIL (INDIA) LTD

NEW DELHI

OF GAS
SPECIFICATION
0001-01-04-02-001
REV- 0
Page 3 of 52
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.
5.2
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.
6.0
WELDING PROCESSES
6.1
Welding of various materials under this specification shall be carried out using the
following process.
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.
7.0
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.
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)
i)
10.2
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.
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
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)
On the first 100 welded joints corresponding to each automatic GMAW and
semi automatic FCAW welding procedures used.
b)
When welds are repaired.
c)
When in the opinion of COMPANY, Radiography Testing is required to

confirm or clarify defects indicated by Ultrasonic Testing.
d)
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)
On the first 10 welded joints corresponding to each automatic GMAW and

semi-automatic FCAW welding procedures used.
b)
When welds are repaired.
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c)
12.5.4
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
Weld quality as judged on the basis of the acceptability criteria mentioned below:
12.6
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.
ii)
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.
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
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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
CHARPY V-NOTCH IMPACT TESTING
1.6.1
Specimens shall be taken from the position indicated in FIG.1 of this specification.
The test specimens will be prepared in accordance with ISO R 148. Charpy VNotch specimens shall have dimensions as given in Fig.3 of the specification.
Three (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.
Note 2:
Only one value is permitted to be lower than average value up to the

value specified.
1.7
BEND TEST REQUIREMENTS

The Bend test specimens shall be made 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:
1.3
a)
Type of Ultrasonic testing equipment to be used
b)
Type and dimensions of transducers
c)
Frequency range
d)
Details for calibration
e)
Coupling medium
f)
Inspection technique
g)
Reference to the welding procedure where it is intended to adopt the

specification
h)
Temperature range of the joints to be inspected
I)
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)
Ultrasonic equipment and coupling medium
b)
Sample sections for calibration of instruments
c)
Equipment for cleaning of surface to be examined
d)
Rules calibrated in centimeters for exact location of the position of defects.
The characteristics of the above listed instruments and equipment shall guarantee:
a)
The required standards of the inspection procedure previously established

and approved by the COMPANY are satisfied
b)
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.
b)
The regulation control shall be accurate to within 1 dB and this accuracy

shall be certified by the instrument manufacturer.
c)
May be powered by a battery or an electric generator. In the first case, the

autonomy of operation (endurance) of the instrument shall be sufficient to
carry 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.
1.6
PROBES
The probes used shall have dimensions, frequencies, and a refraction angle suited
to the type of steel, the diameter, and the thickness of the pipeline and to the joint
design.
1.6
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.
1.7
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)
Calibrate the equipment
b)
Perform an operational test under production conditions
c)
Interpret the screen picture
d)
Evaluate the size and location of reflectors
e)
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
INTRODUCTION
2.0
REFERENCE DOCUMENTS
3.0
APPROVED AGENCIES
4.0
AUT SYSTEM
5.0
COUPLING
6.0
SEARCH UNITS
7.0
CALIBRATIONS
8.0
PROCEDURE
9.0
TRAINING AND QUALIFICATION
10.0
FIELD EXAMINATIONS AND REPORTING
11.0
INTERPRETATION OF RESULTS
12.0
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
TRAINING AND QUALIFICATION
1.
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.
2.
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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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.
3.
4.
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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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.
3.0
PROCEDURE
3.1
The Radiography examination procedure to be adopted shall be submitted by the

CONTRACTOR as per Exhibit - F.
3.2
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)
Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.
iii)
Type 2 and 3 films as per ASTM E-94 shall be used.
iv)
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.
v)
Radiography identification system and documentation for Radiography

interpretation reports and their recording system.
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3.3
The CONTRACTOR shall qualify each procedure in the presence of the COMPANY
prior to use.
3.4
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.
3.5
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.
3.6
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.
3.7
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.
3.8
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.
3.9
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.
3.10
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.
3.11
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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3.12
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.
3.13
COMPANY shall have free access to all the CONTRACTOR's work facilities in the
field.
3.14
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0
RADIATION SOURCE
4.1
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.
4.2
Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 red. (360) If it is
impossible to place the radiation source inside the pipe, the weld will be inspected
with the source on the outside. An overlap of at least 40 mm at the ends of each
film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
5.0
LEVEL OF QUALITY
The quality level of Radiography sensitivity required for Radiography inspection
shall be at least equivalent to the values in FIG.5.
6.0
PENETRAMETERS
6.1
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
PROTECTION AND CARE OF FILM
8.1
All unexposed films shall be protected and stored properly as per the requirements
of API 1104 standard and ASTM E.94.
8.2
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.
9.0
RE-RADIOGRAPHY
9.1
The weld joints shall be re-radiographed in case of unsatisfactory quality of the

radiographs, at the expense of the CONTRACTOR.
9.2
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.
9.3
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.
9.4
10.0 QUALIFICATION OF RADIOGRAPHERS
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10.1
Pipeline radiographers shall be qualified in accordance with the requirement of API

1104 and to the full satisfaction of COMPANY.
10.2
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.
11.0
PRESERVATION OF RADIOGRAPHS
11.1
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.
11.2
All radiographs shall become property of the COMPANY.
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.
12.2
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.
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
DISPLAY OF SAFETY INSTRUCTIONS
14.1
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
CONTRACTOR shall maintain first aid facilities for its employees and those of
subcontractors.
16.2
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.
16.3
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.
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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Sheet 1 of 3
EXHIBIT- A
A:
(ELECTRODE QUALIFICATION TEST RECORD)
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
GAIL (INDIA) LTD

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:
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EXHIBIT A (CONTD.)
Sheet 2 of 3
C.
D.
Impact Test Results

Test Temperature :
Notch in :
Type of Specimens (Charpy) :
Size of Specimens :
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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EXHIBIT A (CONTD.)
Sheet 3 of 3
Macro Test Results
Fracture Test Results
Remarks
F.
Other Test Results
1.
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)
GAIL (INDIA) LTD

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

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------------------------APPROVED BY
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SPECIFICATION
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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)
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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

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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
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION FOR GEOTEXTILE BAGS

FOR ANTI-BUOYANCY
SPECIFICATION
0001-01-04-02-002
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Page 1 of 6
TABLE OF CONTENTS
1.0
SCOPE
2.0
DESIGN
3.0
MATERIAL
4.0
DELIVERY, STORAGE, HANDLING
5.0
MARKING
6.0
7.0
INSTALLATION
9.0
DOCUMENTATION
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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.
2.2
Composition and the details of materials shall be as per recommendation of anufacturer
2.3
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.
b.
Geo-textile bags shall be of top loading fabric-type made from woven

polypropylene material.
c.
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.
2.4
Manufacturer shall take prior approval from Owner on details of geo-textile bags and
design calculations.
2.5
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.
2.6
The proposed bags and associated straps etc. shall not be detrimental to the pipeline
coating in any manner.
2.7
Repair of bags, in any manner is not permitted.
3.0 MATERIAL
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3.1
The body fabric must be treated for UV protection and longevity. The weight of the
2
body fabric must be a minimum of 400 gms/m .

3.2
All material used in the fabrication of geo-textile bags such as webbing, lifting loops,
threads etc. shall be polypropylene material.
3.3
All webbing must have a minimum individual tensile rating of at least 2268 kg. With a
combined safety rating of 4 times the capacity.
3.4
Body fabric must have a maximum elongation rating of 15% and be stable within a pH
range between 2 to 12.
3.5
All testing should be as per ASTM or equivalent standards
4.0 DELIVERY, STORAGE AND HANDLING

4.1
Geo-textile bags shall be delivered on pallets with a black protective cover for easy
handling and storage.
4.2
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.
5.2
Each geo-textile bag shall be marked by indelible paint or other suitable methods with
the following minimum information:
a.
b.
Product model
Name of Manufacturer
c.
Dimensions of bag in mm.
d.
Weight carrying capacity (Total weight when filled)
e.
Year, month of manufacture and product batch number
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
The geo-textile bags shall be filled by using proper sized filling hoppers with appropriate
stone as recommended by manufacturer.
7.2
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.
7.3
Trailers with rails or strapping to secure the load shall be used for transportation to site.
The bags shall not be stacked.
7.4
Weights are to be kept in upright and leaning in supported position in ROU for easy
accesses to the lifting loops.
7.5
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.
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.
8.2
All details of proposed geo-textile bags (such as dimensions, material used etc.) shall be
furnished. Contractor shall highlight any special features if any.
8.3
General arrangement drawings of all items viz. set of geo-textile bags, hopper, loading
arrangement etc.
8.4
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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8.5
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.
8.6
Manufacturer shall highlight any precautions / safety measures to be taken.
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TECHNICAL SPECIFICATION
FOR
PRECOMMISSIONING AND
COMMISSIONING
SPUR LINES OF CHAINSA-JHAJJAR PIPELINE
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TECHNICAL SPECIFICATION FOR

COMMISSIONING
SPECIFICATION
0001-01-04-02-003
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Page 1 of 15
TABLE OF CONTENTS
1.0
INTRODUCTION
2.0
RESPONSIBILITY OF
CONTRACTOR
3.0
SCOPE OF WORK
3.1
Precommissioning activities
3.2
Commissioning related activities
4.0
DOCUMENTATION
5.0
SPARES AND COMSUMABLES
6.0
SAFETY
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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)
Tap-off
point
at
18 X 85.28
Spur Line
to Bhiwadi

31.6 Km in Sultanpur
Neemrana Line
Hayatpur to
Manesar
Tap-off
point
at
Hayatpur to
Gurgaon

61.14 Km in Chainsa-Jhajjar
line
10 X 5.4
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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0001-01-04-02-003
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absence of this, it shall be considered that the bidder has no deviation.
2.0
Questionnaire as given in Appendix-I duly filled by bidder.
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.
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
GAIL (INDIA) LTD

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and

COMMISSIONING
consumables
as
required
SPECIFICATION
0001-01-04-02-003
for
the
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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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3.0
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.
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.
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.
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The leak check operation shall be considered to be completed when the piping
2
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).
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.
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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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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.
AGREED
NOT
REMARKS
AGREED
1.0
SCOPE
[ ]
[ ]
2.0
DEFINITIONS
[ ]
[ ]
3.0
MANUFACTURER REPRESENTATIVE
[ ]
[ ]
4.0
DOCUMENT FOR PRECOMMISSIONING

AND COMMISSIONING
[ ]
[ ]
5.0
OTHER REQUIREMENTS
[ ]
[ ]
6.0
REVIEW/CHECKLISTING/INSPECTION/COORDINATION
[ ]
[ ]
7.0
COMMISSIONING
[ ]
[ ]
8.0
CONSUMABLES
[ ]
[ ]
9.0
SPECIAL REQUIREMENTS
[ ]
[ ]
10.0
SAFETY
[ ]
[ ]
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)
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SPECIFICATION FOR LONGITUDINAL SEAM

SUBMERGED ARC WELDING (LSAW) LINE
PIPE (ONSHORE)
DOCUMENT No.
S-04-02-001
REV-0
Page 1 of 36
Abbreviations:
ASTM
American Society for Testing and Materials
API
American Petroleum Institute
ID
Inside Diameter
LSAW
Longitudinal Seam Submerged Arc Welded
HAZ
Heat Affected Zone
NDT
Non Destructive Testing
NPS
Nominal Pipe Size
OD
Outside Diameter, Specified
WT
Wall Thickness, Specified
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CONTENTS
1
SCOPE
REFERENCES
PROCESS OF MANUFACTURE AND MATERIAL
MATERIAL REQUIREMENTS
DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES
10
MARKING
11
COATING AND PROTECTION
12
DOCUMENTS
14 (New)
INSPECTIONS OF FIELD TESTS & WARRANTY
APPENDIX-B
REPAIR OF DEFECTS BY WELDING (NORMATIVE)
APPENDIX-C
REPAIR WELDING PROCEDURE (NORMATIVE)
APPENDIX-F
SUPPLEMENTARY REQUIREMENTS (NORMATIVE)
SR 5
FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR PIPES OF

SIZE 4 OR LARGER
SR 6
DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR LARGER,

GRADE X52 OR HIGHER.
SR 19
ADDITIONAL FRACTURE TOUGHNESS

REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR PSL 2 PIPE
APPENDIX-H
PURCHASER INSPECTION (NORMATIVE)
APPENDIX-I
MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)
ANNEXURE-I
MANUFACTURING PROCEDURE SPECIFICATION
(New)
ANNEXURE-II
FIRST DAY PRODUCTION TESTS
(New)
ANNEXURE-III
INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING
(New)
FIGURE 6.2.6.1
METALLOGRAPHIC SPECIMEN EXTRACTION PLAN
FIGURE 6.2.6.2
LOCATIONS FOR HARDNESS MEASUREMENT
FIGURE 7.8.3
PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD
FIGURE9.8.5.2
REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM
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1.0
SCOPE
1.1
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
GRADES
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 16 through 48 (both sizes
included)
2.0
References
2.1
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
: 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.
ASME IX
ASME B31.8
: Boiler & Pressure Vessel code: Welding & brazing quality.

: Gas Transmission & Distribution piping system.
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OISD 141
API RP 5 L1
: Oil Industries safety distribution piping system

: Recommended practice for railroad transmission of line pipe
5.0
Process of Manufacture and Material
5.1
PROCESS OF MANUFACTURE
Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured
as per this specification:
5.2
Welding Process
Submerged Arc Welding as per para 5.1.2.2.1
Type of Pipe
per para 5.1.3.5
Longitudinal Seam Submerged Arc Welded Pipe as
Type of Seam Weld

para 5.1.4.3
Submerged Arc Weld (Longitudinal Seam) as per
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
CHEMICAL PROPERTIES
6.1.1 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.
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Table - 2B: PSL 2 Chemical Requirements for Heat and Product Analyses by
Percentage of Weight
Element
Product Analysis (percent by weight )
0.16
max.
Mn
1.50
max. (For Grade B
1.60
max. (For Grade X56 to X70)
0.15
min.
Si
0.45
to X52)
max.
0.015
max.
0.02
max.
Al
0.07
max.
Nb
0.05
max.
0.08
max.
Ti
0.04
max. (For Grade B
0.06
toX60)
Cr
0.20
max.
Mo
0.10
max.
Cu
0.35
max.
Ni
0.20
max.
0.012
max.
0.0005
max.
Note: g (New)
i.
V+Nb+Ti shall not exceed 0.1 5%
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.
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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
Carbon Equivalent (PSL 2 Only)
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:
6.2
CE (Pcm )
0.20 %
CE (IIW )
0.40 %
MECHANICAL PROPERTIES
6.2.1 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
Permissible in excess of SMYS. Psi (MPa)

19,000 (131)
X52 TO X65
22,000(152)
X70 and Above
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 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
Fracture Toughness Tests
6.2.5.2
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
Dimensions, Weights, Lengths, Defects and End Finishes
7.2
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
Tolerances
16 and < 20
3 mm
20 and 36
+ 3 mm, 0.25% of specified OD
>36
3 mm.
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
Tolerance
<36 :
0.5%of OD
>36
< 5mm
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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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
JOINTERS
Jointers on pipes are not permitted.
7.8
WORKMANSHIP AND DEFECTS
7.8.1
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
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
PIPE ENDS
7.9.1
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
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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
Inspection and Testing
9.2
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
TESTING OF MECHANICAL PROPERTIES
9.3.1
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
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.
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
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
HYDROSTATIC TESTS
9.4.1
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.
DIMENSIONAL TESTING
9.5
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.
NON DESTRUCTIVE INSPECTION
9.8
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 :
Level I, II, III inspector
Supervision
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 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
Radiological Inspection-Weld Seams
9.8.4.1
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
Ultrasonic and Electromagnetic Inspection
9.8.5.1
Equipment
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.
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 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.
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 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
TEST METHODS
9.10.3
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
RETESTS
9.12.1
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
REPROCESSING
This para stands cancelled.

10
Marking
10.1
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
Coating and Protection
11.1
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
Documents
12.1
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
B.I. 2
WELD SEAM OF WELDED PIPE
B. 1.2.1 Repaired welds shall be inspected both by X-ray and UT.

B.3
Procedure for Repair of Submerged-Arc and Gas Metal-Are Welds
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
Following requirements shall also be complied with for repair welding;
a.
No repair of weld seam is permissible after cold expansion.
b.
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.
Repair welding shall be executed only after specific approval by Purchaser
Representative for each repair.

e.
No repair of a repaired weld is permitted.
f.
The repair weld shall be performed with a minimum of two passes.
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.
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AFPENDIX- C
C.2
Repair Welding Procedure Qualification
C.2.2
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
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
Flattened specimen shall not be used.
SR 5.5 This para stands deleted.

SR 5A
Shear Area
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
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
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
1.3.4 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
150 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 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.
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ANNEXURE I (NEW)
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)
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)

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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FIGURE: 6.2.6.1
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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 HELICAL (SPIRAL)

SEAM SUBMERGED ARC WELDED (HSAW)
LINE PIPE (ONSHORE)
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SEAM SUBMERGED ARC WELDING
(HSAW) LINE PIPE (ONSHORE)
DOCUMENT No.
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Abbreviations:
ASTM
API
ID
Inside Diameter
HSAW
Helical Seam Submerged Arc Welded
HAZ
Heat Affected Zone
NDT
NPS
Nominal Pipe Size
OD
WT
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CONTENTS
1
SCOPE
REFERENCES
10
MARKING
11
12
DOCUMENTS
14
(New) INSPECTIONS OF FIELD TESTS & WARRANTY
APPENDIX-B
APPENDIX-C
REPAIR WELDING PROCEDUR (NORMATIVE)
APPENDIX-F
SR 5
FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR

PIPES OF SIZE 4 OR LARGER
SR 6
DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE

20 OR LARGER, GRADE X52 OR HIGHER.
SR 7

REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH) FOR
PSL 2 PIPE
APPENDIX-H
APPENDIX-I
MARKING INSTRUCTIONS FOR API LICENSEES

(NORMATIVE)
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ANNEXURE-I
ANNEXURE-II
FIRST DAY PRODUCTION TESTS (New)
FIGURE 6.2.6.1
FIGURE 6.2.6.2
LOCATIONS FOR HARDNESS MEASUREMENT
FIGURE 7.8.3
PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD

BEAD
FIGURE9.8.5.2
SEAM
REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD
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1.
SCOPE
1.1

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 requirements of API Spec. 5L, Forty-Third Edition, 2004 on line pipe as Product
1.2

Line pipe supplied to this specification shall conform to Product Specification Level PSL
2.
1.3
GRADE
1.4
DIMENSIONS
This specification shall be applied to line pipe of size 18 through 48 (both sizes
included)
2.0
References
2.1
The latest edition (edition enforce at the time of issue of enquiry) of following additional
references are included in this specification:
ASTM E 92
Test Method for Vickers Hardness of Metallic Materials.
ASTM R 112
Standard Test Methods for Determining Average Grain Size.
BS 5996
Specification
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for
the

Acceptance
Level
DOCUMENT No.
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for
Internal
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Imperfection in Steel Plate, Strip and Wide Flats, based on

Ultrasonic Testing.
ASME IX
ASME B31.8
Gas Transmission & Distribution piping system.
OISD 141
Oil Industries safety distribution piping system
Recommended practice for railroad transmission of

line pip
API RP 5 L1
5
Boiler & Pressure Vessel code: Welding & brazing

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

5. 1.3.11
Type of Seam Weld
: 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
MATERIAL
5.3.3
(New)
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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.
6.1
CHEMICAL PROPERTIES
6.1.1
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
Product Analysis (percent by weight)
0.16
max
Mn
1.50
max. (For Grade B to X52)
1.60
Si
max (For Grade X56 to X70)
0.15
min
0.45
max
0.015
max
0.02
max
0.07
max
Al
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Nb
0.05
max.
0.08
max.
Ti
0.04
max. (For Grade B
0.06
Cr
0.20
max.
Mo
0.10
max.
Cu
0.35
max
Ni
0.20
max
0.012
max
0.0005
to X60)
max
Note:
g (New)
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)
Note: i (New)
6.1.2 Elements Analysed
specification shall be analyzed and reported, even if those are not purposely added but
are present as residuals only.
6.1.3

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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

For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the
following limits:
6.2
6.2.1
CE (Pcm)
0.20
CE (IIW)
0.40
Tensile Properties
The finished pipe shall conform to the requirements of Table 3B of API Spec 5L and as
modified herein.
strength (SMYS) but in no case it shall exceed the limits specified here under:
API Spec 5 L Grade
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.
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
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

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
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
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)
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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
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
Tolerance
18
3mm
> 20 and <36

>36
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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
Tolerance
36
0.5% of OD
>36
<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
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
7.8
7.8.1

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

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
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
Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the
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
PIPE ENDS
7.9.1
General
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

Heat Analysis
Where the steel mill is not a part of an integrated pipe mill, heat analysis shall be
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

product analysis from skelp may be used provided the traceability of samples is
guaranteed.
9.3
9.3.1
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

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
D =
gauge length (mm)

diameter of the test specimen (mm)
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

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

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
HYDROSTATIC TESTS
9.4.1

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
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 he free of defects in the finished condition.
9.8

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
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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(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 alt other NDT methods

Evaluation of indications
Supervision
Level II or Level III inspector

(in case evaluation is by Level I
inspector)
9.8.3
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.
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 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
Radiological Inspection-Weld Seams
9.8.4.1
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.
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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
Ultrasonic and Electromagnetic inspection
9.8.5.1
Equipment
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

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.
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.
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)
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.
9.8.7
exceed 25 gauss when measured with Hall-effect gauss meter. All residual magnetism
9.9

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
TEST METHODS
9.10.3
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
RETESTS
9.12.1
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
10
Marking
10.1
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

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
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
LINE PIPE TRACEABILITY 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:
- 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.
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APPENDIX B
B.1.2
Weld Seam of Welded Pipe
B.I.2.1
Repaired welds shall be inspected both by X-ray and UT.
B.3
Procedure for Repair of Submerged-Arc and Gas Metal-Arc Welds
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
Following requirements shall also be complied with for repair welding:

a.
No repair of weld seam is permissible alter hydrostatic testing.
b.
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 repair per pipe are allowed.
d.
Repair welding shall be executed only

Purchaser Representative for each repair.
e.
No repair of a repaired weld is permitted.
f.
The repair weld shall be performed with a minimum of two passes.
after specific approval by
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.
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APPENDIX-C
C.2
Repair Welding Procedure Qualification
C.2.2
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
SR5
Larger
Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 1/2 or
SR 5.1
The Manufacturer shall perform Charpy V-notch 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 5.5
This para stands deleted.
SR 5A
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%.
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 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.
SR 6
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
more for the specified test temperature.
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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.
SR19
Additional Fracture Toughness Requirements (Transverse Charpy VNotch) 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 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.
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APPENDIX- H
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
1.0
General
1.1
Marking shall also include Purchase Order number/item number, pipe number, heat
number and weight.
1.2
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
1.3.4
Specified Dimensions:
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
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)
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.
- 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.
- 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.
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.
- 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.
- Dimensional tolerances, frequency of checking, measurement and record in a tabular
form including
details of instruments and equipments proposed.
welds.
- Hydrostatic testing including details of testing equipment, procedure and the relevant
test pressure
calculations.
- Marking details.
requirements of submission of manufacturing procedure details can be moderated subject to
agreement between Purchaser and Manufacturer.
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ANNEXURE -II (NEW)

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.
All pipes shall be examined visually for dimensional tolerances and apparent
surface defects.
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.
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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.
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:
-
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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ANNEXURE III (NEW)

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.
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FIGURE : 6.2.6.1
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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
SEAMLESS LINE PIPE (ONSHORE)
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STADARD SPECIFICATION FOR SEAMLESS

LINE PIPE (ONSHORE)
DOCUMENT No.
S-04-02-003
REV-0
Page 1 of 6
CONTENTS
S.No.
Description
Page No.
INTENT OF SPECIFICATION
SCOPE OF WORK
COVERAGE
REFERENCES
MANUFACTURING PROCESS
INSPECTION & TESTING
MARKING & DESPATCH
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DOCUMENT No.
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1.0
INTENT OF SPECIFICATION
1.1

Seamless Pipes in accordance with the requirements of API (American Petroleum
Institute) Specification 5L- 2000 (Forty Second Edition).
1.2
Unless modified and referred by this specification the requirements of API Spec. 5L2000 shall be valid.
2.0
SCOPE OF WORK
2.1
The scope of the tenderer includes manufacture / supply, inspection / testing , marking
& packaging and despatch of seamless linepipes as indicated in the Material Requisition
(MR).
2.2
All codes and standards for manufacture, testing, inspection, etc, shall be of latest
edition.
2.3
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.
3.0
COVERAGE
3.1
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.
4.0
REFERENCES
4.1
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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DOCUMENT No.
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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
MANUFACIURING PROCESS
5.1
Steel made by acid Bessemer process shall not be acceptable.
5.2
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.
5.3
Seamless pipes shall not have any circumferential seam joint in a random length.
6.0
6.1
All pipes shall be hydrostatically tested. The test mill pressure shall be as follows:
GROUP 1 (SEAMLESS,ERW & SPIRAL WELDED)
A
S No.
CARBON STEEL
(i)
(ii)
(iii)
(iv)
(v)
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
(vi)
ASTM
S No.
(i)
(ii)
A333 GR.3
&
6,E.R.W
TEST PRESSURE
:
:
:
:
:
ASTM A 530
API 5L
API 5L
API 5L
ASTM A530
ASTM A530
TEST PRESSURE
ASTM A530
ASTM A530
SEAMLESS ALLOY STEEL

MATERIAL STD
ASTM
GR.P1,P12,P11,P22,P5,Pg
ASTM A268 TP 405,TP410
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A335

LINE PIPE (ONSHORE)
DOCUMENT No.
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S No.
SEAMLESS STAINLESS STEEL
(i)
MATERIAL STD
ASTM A312 GR. TP304 ,304L
,304H, 316, 316L, 316H, 321, 347
SEAMLESS NICKEL ALLOY
S No.
(i)
(ii)
(iii)
(iv)
MATERIAL STD
ASTM B161 UNS
ASTM B165 UNS
ASTM A167 UNS
ASTM A407 UNS
NO2200
NO4400
NO6600
NO8800
TEST PRESSURE
ASTM A530
TEST PRESSURE
:
:
:
:
ASTM B161
ASTM B165
ASTM B167
ASTM B407
6.2
Material test certificates (physical properties, chemical composition & heat treatment
report) shall also be furnished for the pipes required.
6.3
Pipe with bevelled ends shall be in accordance with ASME B16.25. Weld contour shall
be as per Figure-2, Type-A.
7.0
MARKING & DESPATCH
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.
7.2
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.
7.3
Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.
7.4
Pipes shall be protected from rust, corrosion & mechanical damage during
transportation, shipment and storage.
7.5
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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DOCUMENT No.
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7.6
Both ends of pipes (Bevelled Ends) shall be protected with wood, metal or plastic cover.
7.7
End protectors to be used on bevelled ends shall be securely and tightly attached with
belt or wire.
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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.
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Page 1 of 34
CONTENTS
1
SCOPE
REFERENCES
10
MARKING
11
12
DOCUMENTS
14
(New) INSPECTIONS OF FIELD TESTS & WARRANTY
APPENDIX-F
SR 5
FRACTURE TOUCHNESS TESTING (CHARPY V-NOTCH) FOR PIPES

OF SIZE 4 OR LARGER
SR 6
DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE 20 OR

LARGER, GRADE X52 OR HIGHER PIPE AND LASER
SR 17
NON DESTRUCTIVE INSPECTION OF WELDS IN

ELECTRIC WELDED PIPE AND LASER WELDED PIPE
SR 19

REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH)
FOR PSL 2 PIPE
APPENDIX-H
APPENDIX-I
MARKING INSTRUCTIONS FOR API LICENSEE (NORMATIVE)
ANNEXURE-I
MANUFACTURING PROCIDURE
(New)
ANNEXURE-II

(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
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Abbreviations:
ASTM
API
ID
Inside Diameter
EW
Electric Welded
HAZ
Heat Affected Zone
NDT
NPS
Nominal Pipe Size
OD
WT
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1. Scope
1.1

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 requirements of API Spec 5L Forty-Third Edition, 2004 on line pipe as Product
1.2

Line pipe supplied to this specification shall conform to Product Specification
Level PSL 2.
1.3
GRADES
1.4
DIMENSIONS
This specification shall be applied to line pipe of size 4 1/2 through 20 (both sizes
included),
2.
References
2.1
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
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: Specification for the Acceptance Level for Internal

Imperfection in Steel Plate, Strip and Wide Flats, based
on Ultrasonic Testing.
DOCUMENT No.
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OISD 141
: 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
ASME IX
ASME B31.8
API RP 5 L
5
5.1
PROCESS OF MANUFACTURE
Following paragraphs of API Spec 5L shall be applicable to the line pipe
manufactured as per this specification:
Welding Process
Electric Welding as per para 5.1.2.1.2.
Type of Pipe
Electric Welded Pipe as per para 5.1.3.3 &

5.1.3.3.2.
Type of Seam Weld
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
COLD EXPANSION
Pipes furnished to this specification shall be non-expanded.
5.3
MATERIAL
5.3.3 (New)
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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5.4
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.
6.1
CHEMICAL PROPERTIES
6.1.1
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
Product Analysis (percent by weight)
0.16
max
Mn
1.50
max (For Grade B to X52)
1.60
0.15
min
0.45
max
0.01
max
0.02
max
Al
0.07
max
Nb
0.05
max
0.08
max
Ti
0.04
max (For Grade B to X60)
0.06
Cr
0.20
max
Mo
0.10
max
Cu
0.35
max
Ni
0.20
max
0.012
max
0.0005
max
Si
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Note:
g (New)
i.
V+Nb+Ti shall not exceed 0.15%.
ii.
Cu+Ni shall not exceed 0.40%.
iii.
Al/N shall be min. 2.
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Note: h (New)
Note: i (New)
6.1.2
Elements Analyzed
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

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

For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with
the following limits:
CE (Pcm)
0.20 %
CE (IIW)
0.40 %
6.2
6.2.1
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.
strength (SMYS) but in no case it shall exceed the limits specified here under:
API Spec 5L Grade
Permissible in excess of SMYS. psi (MPa)
19,000 (131)
X52 to X56
22,000(152)
X70
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.
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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)
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

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
6.2.6.1 (New)
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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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
6.2.7.1 (New)
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:
Where
D -
Specified outside diameter of pipe, mm
Specified wall thickness of pipe, mm
1.4 -
Peaking factor
e -
Strain
Minimum value of 'e' shall be as follows:

Grade of Steel
Min e' value
Gr. B
0.1425
X-42
0.1375
X-46
0.1325
X-52
0.1250
X-60
0.1125
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X-65
0.1100
X-70
0.1075
6.2.7.3 (New)
Procedure
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
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
Tolerance
>4 1/2 and18
0.75 % of Specified OD or 3 mm whichever is smaller
20
+3 mm, - 0.25% of Specified OD
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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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
Tolerance
10
2mm
>12
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
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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
7.7
JOINTERS
7.8
7.8.1
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

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
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

Sections of the pipe containing cracks, sweats and leaks shall he cut off as per the
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
PIPE ENDS
7.9.1
General
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 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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Inspection and Testing
9.2
9.2.1
Heat Analysis
Where the steel milt is not a part of an integrated pipe mill, heat analysis shall be
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 arc also represented.
9.2 2.2
Sampling Method
9.2.2.22 Welded Pipe

product analysis from skelp may be used provided the traceability of samples is
guaranteed.
9.3
9.3.1
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
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

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

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
HYDROSTATIC TESTS
9.4.1

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

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
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.
For UT
(i)
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
9.8.3
Evaluation of indications
Supervision

Level II or Level III inspector (in case
evaluation is by Level I inspector)
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.
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 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
Ultrasonic and Electromagnetic Inspection
9.8.5.1
Equipment
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
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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.
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.
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/Area on either side of the Longitudinal Weld Seam (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.
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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.)
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.
9.8.7
e.
9.9

exceed 25 gauss when measured with Hall-effect gaussmeter. All residual
magnetism measurements shall be recorded.
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
TEST METHODS
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.
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9.12
RETESTS
9.12.1
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
REPROCESSING
10
Marking
10.1
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
Coating and Protection
11.1
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
Documents
12.1
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
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
SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 or
Larger
SR 5.1
The Manufacturer shall perform Charpy V-notch test for determining Shear Area.
SR 5.3
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.
SR 5.4
SR 5.5
This para stands deleted.
SR 5A
Shear Area
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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SR6
SR6.1
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.
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 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.
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 'lot1. Lot shall be as per SR6.2 as above.
SR17
Nondestructive Inspection of Welds in Electric Welded Pipe and Laser

Welded Pipe
SR 17.1
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
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
1.1
General
1.1.1
Marking shall also include API monogram, Purchase Order number, item number,
wall thickness (mm), pipe number, heat number and weight.
1.2
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
Sequence of Marking
1.3.4
SPECIFIED DIMENSIONS
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
Length
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)
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.
- 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.
- 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.
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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- 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.
- Dimensional tolerances, frequency of checking, measurement and record in a tabular
form including details of instruments and equipments proposed.
welds.
- Hydrostatic testing including details of testing equipment, procedure and the relevant
test pressure calculations.
- Marking details.
requirements of submission of manufacturing procedure details can be moderated
subject to agreement between Purchaser and Manufacturer.
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ANNEXURE-lI (NEW)
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.
All pipes shall he examined visually for dimensional tolerances and apparent
surface defects.
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.
i.
Two (2) flattening test specimen shall be removed; one specimen shall be tested
with weld at 0 and other at 90.
ii.
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.
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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:

-
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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3-LAYER POLYETHYLENE COATING OF

LINEPIPES (ONSHORE)
GAIL (INDIA) LTD

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LINEPIPES (ONSHORE)
DOCUMENT No.
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CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
PLANT SCALE AND INSTALLATION
4.0
MATERIALS
5.0
FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING
6.0
MEASUREMENT AND LOGGING
7.0
COATING PROCEDURE AND QUALIFICATION
8.0
PIPE SURFACE PREPARATION
9.0
COATING APPLICATION
10.0
11.0
HANDLING, TRANSPORTATION AND STORAGE
12.0
REPAIR OF COATING
13.0
MARKING
14.0
QUALITY ASSURANCE
ANNEXURE-I
COMBINATIONS OF COATING MATERIALS
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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.
b. ASTM D-257
: Standard Test Methods for D-C Resistance or

Conductance of Insulating Materials.
c. ASTM D-543
: Standard Method of Test for Resistance of Plastics

to Chemical Reagents.
d. ASTM D-570
: Standard Method of Test for Water Absorption of

Plastics.
e. ASTM D-638
: Standard Method of Test for Tensile Properties of

Plastics.
f. ASTM D-792
: Standard Test Method for Density and Specific

Gravity (Relative Density) of Plastics by
Displacement.
g. ASTM D-1238
: Test Method for Flow Rates of Thermoplastics by

Extrusion
h. ASTM D-1525
: Test Method for Vicat Softening Temperature of

Plastics
i. ASTM D-1603
Test Method for Carbon Black in Olefin Plastics
j. ASTM D-1693
: Test Method for Environmental Stress Cracking of

Ethylene Plastics
k. ASTM D-2240
: Test Method for Rubber Property

Durometer Hardness
l. ASTM D-3895
Test Method for Oxidative-induction Time of

Polyolefins by Differential Scanning Calorimetry
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
: Recommended Practice for Railroad

Transportation of Line pipe.
o. API RP 5LW
: Transportation of Line Pipe on Barges and Marine

Vessels
p. DIN EN 10204
Metallic Products Types of Inspection Documents
q. DIN 53735
: Testing of Plastics: Determination of Melt Index of

Thermoplastics.
r. ISO 8502-3
: 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
: Quality Systems : Specification of Production and

Installation
t. ISO 11124
: Preparation of Steel Substrates Before Application

of Paints and Related Products
u. SIS 055900
: Preparation of Steel Substrates before Application

of Paints and Related Products -Visual
Assessment of Surface Cleanliness
v. API 5L
w. ASME B31.8
Specification for Line Pipe
: Gas Transmission and Distribution Piping

Systems.
x. ASME B31.4
: Liquid Transportation Systems for Hydrocarbons,

Liquid Petroleum Gas, Anhydrous Ammonia, and
Alcohols
y. CSA Z245.20-98
: External Fusion Bond Epoxy Coating for Steel

Pipe.
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
PLANT SCALE AND INSTALLATION
3.1
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.
3.3
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.
3.4
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.
3.5
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.
3.6
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.
3.7
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).
4.0
MATERIALS
4.1
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,
4.2
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.
4.3
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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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
CONTRACTOR shall be required to use all materials on a date received rotation

basis, i.e. first in- first used basis.
5.0
FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING
5.1
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.
5.2
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.
5.3
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.
5.3.1
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.
5.3.2
Properties
Unit
Requirement
Test Method
g/10
minutes
1 .0 min.
ASTM D1238
a.
Melt Flow Rate

(190C/2.16kg)
b.
Vicat Softening Point
100 min.
ASTM D1525
c.
Specific Gravity
0.926 min.
ASTM D 792
Requirement
Test Method
Properties of Polyethylene Compound

SI. No.
GAIL (INDIA) LTD

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Properties
Unit

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a.
Tensile Strength
@ + 25 C
N/mm2
17 min.
ASTM D 638
b.
Melt Flow Rate

(190DC/2.16kg)
9/10
minutes
0.25 min.
ASTM D 1238 or
DIN 53735
c.
Specific Gravity @
+ 25C
0.926 min.
(MDPE)
0.941 min.
(HDPE)
ASTM D 792
d.
Hardness @ + 25 C
Shore D
50 min.
ASTM D 2240
e.
Water Absorption, 24
hours, @ + 25 C
0.05 max.
ASTM D 570
f.
Volume Resistivity @ +
25C
Ohm-cm
1016min.
ASTM D 257
Dielectric withstand,
1000 Volt/sec rise @ +
25C
Volts/ mm
30,000 min.
ASTM D 149
h.
Vicat
110 min.
ASTM D 1525
i.
Elongation
600 min.
ASTM D 638
j-
Oxidative
Induction Time in Oxygen
at 220C, Aluminum
pan, no screen
Minutes
10
ASTM D3895
k.
Environmental Stress
Crack Resistance
(ESCR) (for F 50) :
-Medium DensityCondition "C
-High
DensityCondition "B"
l.
5.3.3
Softening Point
Carbon Black Content
300
Hours
ASTM D1693
300
2 min.
ASTM D 1603
Properties of Coating System
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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
Kg/cm
8.0 min
5.0 min
DIN 30670
Impact Strength
(Min. of 30 impacts on
b.
body along the length.
No breakdown allowed
when tested at 25 Kv)
Joules
per
mm of coating
thickness
7 min
DIN 30670
c.
Indentation Hardness
@23+/-2C
@70+/-2C
mm
0.2 max
0.3 max
DIN 30670
d.
Elongation at Failure
300 min.
DIN 30670
e.
Coating Resistivity (*)
Ohm - m2
10 8 min.
DIN 30670
Melt Flow
Rate
shall not deviate
by more than
35% of original
value
DIN 30670
Melt Flow
Rate shall not
deviate by more
than 35% of
regional value
DIN 30670
f.
Heat Ageing (*)
9-
Light Ageing (*)
h.
Cathodic Disbondment
@ + 65 C after 30
days
@ + 65C after 48 hrs
mm radius of
disbondment
(**)
Degree of Cure of
Epoxy. Percentage
Cure, H.
Tg
GAIL (INDIA) LTD

NEW DELHI
15 max.
ASTM G42
7 max.
%
C

LINEPIPES (ONSHORE)
95
+3/-2
CSA Z
245.20-98(***)
DOCUMENT No.
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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
COATING PROCEDURE AND QUALIFICATION
7.1
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:
a.
Details of plant(s), location(s), layout, capacity and production rate(s).
b.
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.
c.
Details of process control and inspection equipment required for the coating
process such as temperature control, thickness control, holiday testers, etc
d.
Details of chemical pre-treatment facilities including process control and inspection

equipment for phosphoric acid wash, de-ionised water wash and chromate wash.
e.
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.
f.
Plant Organization Chart and availability of manpower including coating specialist
g.
Details of utilities/facilities such as water, power, fuel, access roads and

communication etc.
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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
j.
Details of instrument and equipment calibration methods including relevant

standards and examples of calibration certificates.
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
Qualification of Procedures
7.4.1
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
Chemical Pre-treatment
7.4.4.1
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
Qualification of Applied Coating
7.5.1
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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a.
Surface cleanliness, surface roughness measurements and dust control immediately

after second abrasive blast cleaning and salt test immediately after De-ionised water
wash.
b.
pH of pipe surface before and after phosphoric acid wash.
c.
visual inspection of chromate coating.
d.
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.
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.
7.7
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.
7.8
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.
7.9
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.
8.0
PIPE SURFACE PREPARATION
8.1
Unless specified otherwise, the pipes shall be supplied free from mill applied oils but
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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.
8.3
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.
8.4
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.
8.6
Chemical Pre-treatment with Phosphoric Acid Solution
8.6.1
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
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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.
Properties
Unit
Requirement
a.
Turbidity
NTU
1 max.
b.
Conductivity
mho/cm
5 max.
Hardness
d.
Total Alkalinity as CaC03
mg/l
2 to 3
e.
Chloride as CI"
mg/l
1 max.
f.
Sulphate as SO4
mg/i
1 max.
g.
pH
Nil
6.5 to 7.5
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 :
1 to 2
After de-ionised water wash
6 to 7
8.6.4
After the deionised water wash, the pipe shall be dried with dry air and preheated to a
temperature of 65C to 85C.
8.6.5
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.
8.7
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
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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.
8.9
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.
8.10
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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8.11
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.
8.13
Chemical Pre-treatment with Chromate Solution
8.13.1
Following completion of abrasive blast cleaning, all pipe surface shall be chemically
pre-treated with a10% strength chromate solution.
8.13.2
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.
8.13.3
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.
8.13.4 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.
8.13.6
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.
8.14
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
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below:
Relative Humidity %
Maximum elapsed time
>80
2 hours
70 to 80
3 hours
<70
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.
9.0
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
Pipe Heating
9 1.1
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.
9.1.2
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.
9.1.3
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.
9.1.4
Temperature of the pipe surface shall be continuously monitored & recorded by

using suitable Instruments such as infrared sensors, contact thermometers,
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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
Temperature measuring & monitoring equipment shall be calibrated twice every shift
and/or as per COMPANY Representative's instruction.
9.1.6
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.
9.2
Pipe Coating
9.2.1
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.
ii.
Grafted co-polymer adhesive application by extrusion, minimum thickness 0.200

mm.
iii.
Polyethylene application by extrusion.
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)
Reinforced
Type (v)
Up to 10 " (273.1 mm)
2.0
2.7
Over l0 (273.1 mm) to below 20" (508.0

mm)
2.2
2.9
From 20" (508.0mm) to below 32" (813.0

mm)
2.5
3.2
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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.
9.2.4
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.
9.2.6
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.
9.2.7
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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9.2.8
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.
9.2.9
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.
9.2.10
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.
9.2.11
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.
9.2.12
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.
10.0
10.1
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.
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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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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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
Repairs occurring on account of the production tests are however excluded from
above mentioned limitations at para 10.4 (d) above.
10.14
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.
10.15
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
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.
11.4
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.
11.5
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
QUALITY ASSURANCE
14.1
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.
14.2
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
The CONTRACTOR shall submit the procedures that comprise the Quality System
to the COMPANY for agreement.
14.4
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.
14.5
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.
14.6
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.
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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)
Adhesive
(Manufacturer)
PE Compound
(Manufacturer)
CORRO-COAT EP-F2001
(JOTUN)
FUSABOND158D
(DUPONT)
SCLAIR 35 BP HDPE
(NOVACOR)
PE 50-8190/8191 (BASF) or
CORRO-COAT EP-F 2001
(JOTUN)
LUCALEN G3510H
(BASF)
LUPOLEN 3652 D SW
00413 (BASF)
PE 50-6109 (BASF) or
CORRO-COAT EP-F
ME 0420 (BORALIS)
HE 3450 (BOREALIS)
CORRO-COAT EP-F 2001

(JOTUN)
LE-149 V (S K
CORPORATION)
ET 509 B (S K
CORPORATION)
SCOTCHKOTE 226N (3M)
ME 0420 (BOREALIS)
PB 48A004
2001/2002HW (JOTUN) or
SCOTCHKOTE 226N (3M)
(GAIL)
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
DOCUMENT No.
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Page 1 of 31
CONTENTS
1
2
3
4
5
6
7
8
9
SCOPE
DEFINITIONS
ABBREVIATIONS
INTERNAL LIQUID EPOXY COATING
COATING MATERIAL
APPLICATION OF THE COATING MATERIAL
PRODUCTION CONTROL
REPAIRS
ANNEX A :
(NORMATIVE) DETERMINATION OF ASH (REFER TO SUB CLAUSE 5.2.5)
ANNEX B :
(NORMATIVE) DRY FILM THICKNESS (REFER TO SUB CLAUSE 5.3.3 AND

7.1.2)
ANNEX C :
(NORMATIVE) RESISTANCE TO GAS PRESSURE VARIATION (REFER TO

SUB CLAUSE 5.3.9)
ANNEX D :
(NORMATIVE) HYDRAULIC- PRESSURE BLISTERING (REFER TO SUB

CLAUSE 5.3.12)
ANNEX E :
(NORMATIVE) POROSITY OF A FILM OF THE COATING MATERIAL ON A

GLASS PANEL
(REFER TO SUB CLAUSE 7.2.6)
ANNEX F :
ANNEX G :
GAIL (INDIA) LTD

NEW DELHI
(NORMATIVE) CURING TEST (REFER TO SUB CLAUSE 7.2.5)

(NORMATIVE) WET-SPONGE TEST (REFER TO SUB CLAUSE 7.2.6)

DOCUMENT No.
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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
- British Standards
- Deutsche Industries Normen
FBE
- Fusion Bonded Epoxy
ISO
- International Organisation of Standardisation
NACE
- 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
- 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
- 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)
Test
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)
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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
Test method
Non-volatile matter by mass a

Ash b
ISO 3251
Annex A
Viscosity c
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See 5.2.2
See 5.2.6
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Adhesion
ISO 2409
See 5.3.4
Buchholz hardness
ISO 2815
See 5.3.5
ISO 7253
See 5.3.6
Resistance to neutral salt spray

Resistance to artificial ageing
See 5.3.7
Bend test (conical mandrel)
ISO 6860
See 5.3.8
Resistance to gas pressure variations
Annex C
See 5.3.9
Resistance to water immersion
ISO 2812-2
See 5.3.10
Resistance to chemicals
- Resistance to cyclohexane
- 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
See 5.2.2
Non-volatile matter by mass Curing agent component a

Viscosity base component
See 5.2.2
Viscosity curing agent

component
Density base component

Density curing agent
component
Ash base component c
Ash- curing agent component c, d
See 5.2.5
See 5.2.5
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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.
APPLICATION OF THE COATING MATERIAL
6.1
6.2
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
Method
Frequency
Coating material
Name of product
Name of manufacturer
Batch number
Visual
examination
At every change of
shift
Acceptance
criteria
As specified
specified
Surface condition
prior to
surface preparation
Visual
examination
Every pipe
As specified
ISO 8501-1
ISO 8503-2
Twice per shift

Twice per shift
As specified
As specified
Visual
examination
Every pipe
Subject to
agreement
Surface condition
after
surface preparation
Surface cleanliness
Surface profile
Surface
imperfections
E.g. dents, laps
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Wet paint (mixed)

Viscosity and
temperature
As specified
Every time paint is

mixed and every
time painting is
interrupted
Environmental
conditions in the
painting area
Ambient temperature
Steel temperature
Relative humidity
Flash point
Instrumental
Instrumental
Instrumental
instrumental
Cured paint film on

pipes
Appearance and
continuity
Dry film thickness
Porosity (pinholes)
Visual
examination
ISO 2808:1997,
Method 10
Wet-sponge test
(annex G)
Spot test
Twice per shift
(a)
Cured paint film on

steel test panels
As described in
Table 5
See table 5
Twice per shift
Paint film on glass

test panels
Porosity (pinholes)
Annex E
As specified
At every change of
shift
As specified
No sagging
As specified
As required
As specified in
Table-5
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.
PRODUCTION CONTROL
7.1.
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
Method
Frequency
Adhesion
ISO 2409
Bend test
ISO 6860
Buchholz
hardness
ISO 2815
Twice
shift
Twice
shift
Twice
shift
Curing test
Annex F
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Acceptance criteria
per Classification 1
per No loss of Adhesion
per Hardness 94
Twice per
shift

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.
9.
9.1.
Handling
Coated pipes shall be handled in such a way that no damaged is caused to the coating.
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
(NORMATIVE) DETERMINATION OF ASH

General
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
Muffle furnace
A2.3
Desiccator, containing an active desiccant
A2.4
Analytical balance, capable of weighing to 1 mg
A.3.
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
(A.1)
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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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

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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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
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
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
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

G1
General
G.2
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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FOR
PIPELINE BALL VALVES
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STANDARD SPECIFICATION FOR

PIPELINE BALL VALVES (ONSHORE)
SPECIFICATION
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CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
DESIGN AND CONSTRUCTION
5.0
INSPECTION AND TESTS
6.0
TEST CERTIFICATES
7.0
PAINTING MARKING AND SHIPMENT
8.0
SPARES AND ACCESSORIES
9.0
DOCUMENTATION
FIG. 4.9
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
REFERENCE DOCUMENTS
2.1
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.
2.2
Reference has also been made in this specification to the latest edition of the
following Codes, Standards and Specifications.
ASME B31.3
Process Piping
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 B16.10
Face to Face and End to End Dimensions of Valves
ASME B16.47
Large Diameter Steel Flanges
ASME B16.25
Butt-welding Ends
ASME B16.34
Valves - Flanged, Threaded and Welding Ends.
API 1104
ASME Sec VIII
ASME Sec IX
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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
- Standard Test Methods and Definitions for Mechanical Testing

of Steel Products
ASTM B-733
- Auto catalytic Nickel Phosphorous Coating on Metals
MSS-SP-6
- Standard Finishes for Contact Faces of Pipe Flanges and

Connecting- end Flanges of Valves and Fittings.
MSS-SP-44
- Steel Pipeline Flanges.
SSPC-VIS-1
- Steel Structures Painting Council Visual Standard.
2.3
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.
3.0
MATERIALS
3.1
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.
3.2
Carbon steel used for the manufacture of valves shall be fully killed.
3.3
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
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
Valve body design shall be either fully welded or bolted. Valve body joints with
threads are not permitted.
4.3
Ball shall be of single piece, solid type construction.
4.4
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,
DN mm (NPS inches) DN mm (NPS inches) DN mm (NPS inches)
Nominal Valve
Size
for Reduced Bore
DN mm (NPS
inches)
50 (2)
50 (2)
600 (24)
500 (20)
80 (3)
50 (2)
650 (26)
550 (22)
100 (4)
80 (3)
700 (28)
600 (24)
150 (6)
100 (4)
750 (30)
600 (24)
200 (8)
150 (6)
800 (32)
650 (26)
250 (10)
200 (8)
850 (34)
700 (28)
300 (12)
250 (10)
900 (36)
750 (30)
350 (14)
250 (10)
950 (38)
800 (32)
400 (16)
300 (12)
1000 (40)
850 (34)
450 (18)
350 (14)
1050 (42)
900 (36)
500 (20)
400 (16)
1200 (48)
1050 (42)
550 (22)
450 (18)
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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.
4.6
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.
4.7
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.
4.8
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.
4.9
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.
4.10 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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4.14
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.
c)
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.
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.
c)
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.
d)
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.
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.
b)
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.
c)
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.
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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.
e)
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.
4.21 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

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.
b)
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:
Pressure Class Rating
Valve Size
Extent of Radiography
ANSI 150 # Class
All sizes
Nil
ANSI 300 # Class
DN 400 mm (16)
DN450 mm (18)
Nil
100%
All sizes
100%
ANSI 600 # Class and above
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.
d)
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.
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)
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.
c)
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)
The valve shall be subjected to at least 100 Open-Close-Open cycles with

maximum differential pressure corresponding to the valve rating.
b)
Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test 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)
Test certificates of hydrostatic and pneumatic tests complete with records of

timing and pressure of each test.
c)
Test reports of radiograph and ultrasonic inspection.
d)
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
PAINTING, MARKING AND SHIPMENT
7.1
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.
7.2
All valves shall be marked as per API 6D. The units of marking shall be metric
except nominal diameter, which shall be in inches.
7.3
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.
7.4
All sealant lines and other cavities of the valve shall be filled with sealant before
shipment.
7.5
Packaging and shipping instructions shall be as per API 6D.
7.6
On packages, following shall be marked legibly with suitable marking ink:

a)
b)
c)
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Manufacturers Name
Valve size and rating
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d)
e)
Tag Number
Serial Number
8.0
8.1
Manufacturer shall furnish list of recommended spares and accessories for valves
required during start-up and commissioning.
8.2
Manufacturer shall furnish list of recommended spares and accessories required for
two years of normal operation and maintenance of valves.
8.3
Manufacturer shall quote for spares and accessories as per Material Requisition.
9.0
DOCUMENTATION
9.1
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.
b)
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.
c)
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.
d)
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.
e)
Clause wise list of deviations from this specification, if any.
f)
Descriptive technical catalogues of the manufacturer.
g)
Installation, Operational and Maintenance Manual.
h)
Copy of valid API 6D Certificate.
i)
Details of support foot including dimensions and distance from valve

centerline to bottom of support foot.
j)
List of recommended spares required during start-up and commissioning.
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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)
Detailed sectional drawings showing all parts with reference numbers and
material specifications.
b)
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.
c)
Welding, heat treatment and testing procedures.
d)
Details of corrosion resistant paint to be applied on the valves.
e)
Design calculation for pressure containing Parts.
f)
Procedure for cycle testing.
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.
9.4
Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six
copies of the following:
9.5
a)
Test certificates as per clause 6.0 of this specification
b)
Manual for installation, erection, maintenance and operation instructions

including a list of recommended spares for the valves.
All documents shall be in English language only.
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FOR
PIPELINE PLUG VALVES
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CONTENTS
Sl. No.
DESCRIPTION
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
5.0
6.0
TEST CERTIFICATES
7.0
8.0
9.0
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
REFERENCE DOCUMENTS
2.1
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.
2.2
following Codes, Standards and Specifications:
ASME B 31.3
Process Piping.
ASME B 31.4
Pipeline Transportation System for Liquid Hydrocarbons

and Other Liquids.
ASME B 31.8
Gas Transmission and Distribution Piping Systems.
ASME B 16.5
Pipe Flanges and Flanged Fittings.
ASME B 16.25
Butt-welding Ends
ASME B 16.34
Valves -- Flanged, Threaded and Welding Ends.
ASME B 16.47
API 1104
Welding Pipelines and Related Facilities.
ASME Sec VIII/IX
Boiler and Pressure Vessel Code.
ASTM A 370
Test Methods and Definitions for Mechanical Testing of

Steel Products.
ASTM B 733
Auto catalytic Nickel Phosphorous Coating on Metals.
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MSS-SP-6
Standard Finishes for Contact Faces of Pipe Flanges and

Connecting-end Flanges of Valves and Fittings.
MSS-SP-44
Steel Pipe Line Flanges.
SSPC-VIS-1
Steel Structures Painting Council Visual Standard.
2.3
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.
3.0
MATERIALS
3.1
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.
3.2
Carbon steel used for the manufacture of valves shall be fully killed.
3.3
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:
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
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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
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
4.3
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
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
Cover shall be bolted to the body and screwed connections are not acceptable.
4.5
Soft seats to achieve a seal between plug and body are not permitted.
4.6
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.
4.7
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.
4.8
Valve design shall ensure repair of gland packing under full line pressure.
4.9
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.
c)
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.
4.10 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)
b)
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.
c)
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.
d)
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.
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.
b)
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.
c)
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
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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)
Direction of operation of hand wheel or wrench shall be in clock-wise

direction while closing the valve.
e)
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
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
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.
5.1.3
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#
All sizes
Nil
ANSI Class 300#
DN 400mm (16)
Nil
ANSI Class 600#

and above
DN 450mm (18)
100%
All sizes
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.
b)
Test certificates of hydrostatic and pneumatic tests complete with records of

timing and pressure of each test.
c)
Test reports of radiography and ultrasonic inspection.
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d)
Test report on operation of valves conforming to clause 5.1.8 and 5.1.9 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
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.
7.2
All valves shall be marked as per API 6D. The units of marking shall be metric
except nominal diameter, which shall be in inches.
7.3
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.
7.4
All sealant lines and other cavities of the valve shall be filled with sealant before
shipment.
7.5
Packaging and shipping instructions shall be as per API 6D.
7.6
On packages, the following shall be marked legibly with suitable marking ink:
8.0
a)
Order Number
b)
Manufacturers Name
c)
Valve size and rating
d)
Tag Number.
e)
Serial Number

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8.1
Manufacturer shall furnish list of recommended spares and accessories for valves
8.2
two years of normal operation and maintenance of valves.
8.3
9.0
DOCUMENTATION
9.1
9.2

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.
b)
Sectional drawing showing major parts with reference numbers and material
specification.
c)
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.
d)
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.
e)
Descriptive technical catalogues of the manufacture.
f)
Clause wise list of deviation from the specification, if any.
g)
Installation, Operational and Maintenance Manual.
h)
Copy of valid API 6D Certificate.
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)
Detailed sectional drawings showing all parts with reference numbers and
materials specification.
b)
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)
Fabrication details of all valves.
d)
Welding, Heat treatment and Testing procedures.
e)
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.
9.4
Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six
a)
Test certificates as listed in clause 6.0 of this specification.
b)
Manual for installation, erection, maintenance and operation instructions

including a list of recommended spares for the valves.
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ABOVE GROUND
INSTALLATION
UNDER GROUND
INSTALLATION
FIGURE- 4.6
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SPECIFICATION
FOR
GAS POWERED VALVE ACTUATORS
SPECIFICATION NO.
GAIL (INDIA) LTD
NEW DELHI
SPECIFICATION FOR GAS

POWERED VALVE ACTUATORS
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Page 1 of 14
TABLE OF CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
ACTUATOR SIZING
4.0
DESIGN FEATURES
5.0
COATING
6.0
7.0
NAME PLATE
8.0
SHIPPING
9.0
DOCUMENTATION
10.0
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.
1.2
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.
13
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.
1.4
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
Gas Transmission and Distribution Piping System:
b. ASME B 16.5
Pipe flanges and Hanged Fittir
c.
ASME B16.47
Large dia Steel Flanges NPS 26 through N PS 60
d.
ASME SEC. VIII
Boiler and Pressure Vessels Code.
e. ANSI B2. I
Pipe Threads, General Purpose
f. NEC
National Electric Code
g. IEC
International, Electrotechnical commission
h. NEMA
National Electrical Manufacturers Association
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
Actuator manufacturer shall provide the complete model no. decoding for actuators,
limit switches and solenoid valves.
3.3
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.
3.4
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
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.
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.
4.3
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.
4.4
All materials in contact with natural gas shall he suitable for the gas composition
attached with this specification.
4.5
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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movement between these connections when the valve is actuated by the

actuator under any load.
b)
Actuator shall be suitable for installation on a vertical stem unless otherwise

specified in the data sheet.
4.8
Provision shall be made to prevent accidental pressure build up in the actuator.
4.9
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.
4.10
A position indicator on the actuator shall show the valve in the open, closed or
partially open positions.
4.11
Bearings shall be factory packed with grease and shall not require additional
lubrication for the life of the actuator.
4.12
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.
4.13
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.
4.14
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,
4.15
A high pressure dehydrating fiter cartridge shall be provided to remove condensate,

moisture, foreign particles and any corrosive contaminants from pipeline gas.
4.16
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.
4.17
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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4.18
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.
a)
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).
b)
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.
4.19
The stroke of the Actuator shall he easily adjustable in steps of maximum 0.5 for Ball
Valves.
4.20
Speed control nozzles for adjusting the valve speed over a wide range shall be
provided.
4.21
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.
4.22
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.
4.23
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.
4.24
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.
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4.25
All mounting accessories needed for installing the actuator, tanks etc. are in
manufacturers scope of supply.
4.26
The interconnecting cabling, interconnecting pipe work between the actuator and the
valve, adapters, tubing, cable glands, junction box are in manufacturers scope of
supply.
4.27
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.
4.28
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.
5.0
COATING
The actuator. including gear boxes and piping, shall be coated as described below:
5.1
Removal of all rust by means of emery cloth or wire brush.
5.2
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).
6.0
6.1
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.
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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
All actuators shall be visually inspected.
6.4
Dimensional check on actuators shall be carried out as per the Purchaser approved
drawings.
6.5
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
All threaded and flanged opening shall be suitably protected to prevent entry of
foreign material.
8.2
The actuator shall be supplied pre-assembled except piping/ tubing, actuator, actuator
control unit, tanks and other accessories shall be packed separately.
8.3
Protective grease oil coating shall be applied on the surface to protect them from
rusting.
8.4
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
DOCUMENTATION
9.1
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.
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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
Manufacturer shall furnish list of recommended spares and accessories for actuators
10.2
two years of normal operation and maintenance of actuators.
10.3
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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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GAS COMPOSTION
SL.
PARAMETER
RELIANCE
R-LNG
SPOT
NO
Lean gas at
Vijaipur
Typical
Mole (%)
1
Methane (C1)
94.0
88.51
92.79
90.84
Ethane(C2)
5.0
7.72
5.41
5.02
Propane(C3)
1.0
2.33
1.37
0.68
T-Butane(C4)
0.00
1.18
0.32
0.05
T-Pentane(C5)
0.00
0.07
Hexane(C6)
Carbon Di-oxid C O
3.30
0.19
0.11
0.11
Total Sulphur content
NA
24 ppmw
24 ppmw
H2S
NA
6ppmw
6ppmw
2
8
Nitrogen (N2)
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FOR
SEAMLESS FITTINGS & FLANGES
SIZE UP TO DN 400 mm (16)
GAIL (INDIA) LTD

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(UPTO 400 mm/ 16)
SPECIFICATION
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CONTENTS
Sl. No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MANUFACTURERS QUALIFICATION
4.0
MATERIALS
5.0
DESIGN AND MANUFACTURE
6.0
7.0
TEST CERTIFICATES
8.0
9.0
DOCUMENTATION
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(UPTO 400 mm/ 16)
SPECIFICATION
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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
REFERENCE DOCUMENTS
2.1
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.
GAIL (INDIA) LTD
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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.
3.0
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.
4.0
MATERIAL
4.1
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.
4.2
Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with
the following formula:
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
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be used for other hydrocarbon services, the hardness requirements stated above are
not applicable.
4.5
In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.
5.0
5.1
Flanges such as weld neck flanges and blind flanges shall conform to the requirements
of ASME B16.5.
5.2
Spectacle blind and spacer & blind shall conform to the requirements of ASME B16.48.
5.3
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).
5.4
Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in

accordance with MSS-SP-97.
5.5
Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.6
Flanges and fittings manufactured from bar stock are not acceptable.
5.7
All butt weld ends shall be bevelled as per ASME B16.5/ ASME B16.9/MSS-SP-97 as
applicable.
5.8
Repair by welding on flanges and fittings is not permitted.
6.0
6.1
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 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.
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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.
b)
Test Reports on non destructive testing.
c)
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.
8.0
8.1
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.
8.2
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.
8.3
All flanges and fittings shall be marked as per applicable dimension/manufacturing

standard.
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9.0
DOCUMENTATION
9.1
Prior to shipment, the Manufacturer shall submit six copies of the test certificates as
listed in clause 7.0 of this specification.
9.2
All documents shall be in English Language only.
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FOR
FLANGES & WELDED FITTINGS
(SIZE DN 450 mm (18") AND ABOVE)
GAIL (INDIA) LTD

NEW DELHI

FLANGES &WELDED FITTINGS (SIZE
450 MM (18) AND ABOVE
DOCUMENT NO.
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Page 1 of 7
CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MANUFACTURER'S QUALIFICATION
4.0
MATERIALS
5.0
6.0
7.0
TEST CERTIFICATES
8.0
9.0
DOCUMENTATION
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DOCUMENT NO.
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Page 2 of 7
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
REFERENCE DOCUMENTS:
2.1
Reference has been made in this specification to the latest edition of the following
Codes, Standards and Specifications.
ASME B31.3
Process Piping
ASME B31.4
Pipeline Transportation System for Liquid

Hydrocarbons and Other Liquids
ASME B31.8
Gas transmission and distribution piping system
ASME B16.5
Pipe Flanges and Flanged fittings
ASME B16.9
Factory made wrought steel Butt welding fittings
ASME B 16.25
Butt welding Ends
ASME B16.47
Large diameter steel Flanges
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, Flanges, Fittings

and Unions
MSS-SP-44
Steel Pipeline Flanges
MSS-SP-75
Specification for high Test Wrought Welded fittings
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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.
3.0
MANUFACTURER'S QUALIFICATION:
Manufacturer who intends bidding for fittings must possess the records of a successful
proof test in accordance with the provisions of ASME B16.9 / MSS-SP-75, as applicable.
4.0
MATERIAL:
4.1
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.
4.2
Each heat of steel used for the manufacture of flanges and fittings shall have
Carbon Equivalent (CE) not greater than 0.45 calculated from check analysis in
accordance with the following formula:
CE
4.3
C + Mn + Cr+ Mo + V + Ni+Cu
6
5
15
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
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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
In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.
5.0
DESIGN AND MANUFACTURE:
5.1
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.
5.2
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.
5.3
Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.4
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.
5.5
Fittings such as weldolets etc. shall be manufactured in accordance with MSS-SP97.
5.6
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.
5.7
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.
5.8
The reinforcement of inside weld seam shall be removed for a distance of 100mm
from each end of welded fittings.
5.9
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.
5.10
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
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maintained. Repair welding procedure qualification shall include all tests, which are
applicable for regular production welding procedure qualification.
6.0
INSPECTION AND TESTS:
6.1
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.
6.1.4 The non-destructive inspection shall be carried out as given below:
a)
b)
6.2
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.
c)
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.
d)
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.
e)
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.
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
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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:

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.
b)
Test Reports on radiography, ultrasonic inspection and magnetic particle

examination.
c)
Test reports of heat treatment carried out as per the specification.
d)
e)
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.
8.0
PAINTING, MARKING AND SHIPMENT:
8.1
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.
8.2
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.
8.3
Flange face shall be suitably protected to avoid any damage during transit.
8.4
All flanges and fittings shall be marked as per applicable dimension /

manufacturing standard.
9.0
DOCUMENTATION:
9.1
Prior to shipment, the Manufacturer shall submit six copies of the test certificates
as listed in clause 7.0 of this specification.
9.2
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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
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Page 1 of 10
CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIAL
4.0
6.0
TEST CERTIFICATES
7.0
MARKING, PACKING AND SHIPMENT
8.0
DOCUMENTATION
9.0
BEND MANUFACTURING PROCEDURE QUALIFICATION
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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.
b) ASME B 31.8
: Gas Transmission and Distribution Piping System
c)
MSS-SP-75
: Specification for High Test Wrought Welding Fittings
d)
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
MATERIAL
3.1
Bends shall be fabricated from steel line pipe. The type of pipe to be used for
fabrication of bends shall be indicated in the Work Order. Pipe with positive wall
thickness tolerances shall be used for fabrication of bends.
3.2
Unless specified otherwise in the Work Order, the line pipes for fabrication of bends
shall be procured by Owner.
3.3
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.
3.4
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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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
MANUFACTURE
4.1
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.
4.2
Bends shall be manufactured by high frequency induction heating and forming

method. Once the bending operation has commenced no stoppage shall be
permitted until the entire bend has been completed. If bending temperature,
bending rate, cooling medium volume or heat treatment temperature- depart from
the company approved bend manufacturing procedure, then the pipe shall be
discarded and another bend shall be made in its place.
4.3
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.
4.4
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.
4.5
Unless otherwise specified differently in the PO, the bevels at the ends shall be as
per the relevant pipe specification.
4.6
Bends shall not have any circumferential joint.
4.7
No repair by welding is allowed on any part of the bends.
4.8
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.
4.9
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.
4.10
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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: 0.50 from the specified angle

: 1 % of bending nominal radius (radius as indicated in clause
4.1 above).
Bend Angle
Bend Radius
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
0.95 (tactual - t)
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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Page 5 of 10
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.
b)
Visual inspection
c)
Dimensional and tolerances check as per MSS-SP-75 and requirements of

Section 4.0 of this specification.
d)
Check heat treatment, if carried out, as required and maintain its records.
e)
Temperature against time recorder charts for each induction heating.
f)
The non-destructive inspection on the finished bend shall be carried out as

given below:
-
All seam welds of bends manufactured from SAW pipes shall be 100%
radiographed 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.
g)
A check shall be performed on each bend by passing a gauging pig

consisting of two discs having a diameter equal to 95% of the nominal
internal diameter of the pipe, connected rigidly together at a distance
equal to 500 mm. Details of the gauging pig , including its dimensions
shall be approved by company.
5.2
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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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)
Certificates of non-destructive test/ examination carried out on

bends.
c)
Records of heat treatment, ifcarried out for bends.
d)
Certified reports of dimensional tolerance of bends.
e)
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
MARKING, PACKING AND SHIPMENT
7.1
All bends shall be marked as per MSS-SP-75.
7.2
All loose and foreign material like rust, grease, etc. shall be removed from inside
and outside of the bends.
7.3
One coat of antirust paint shall be applied on the bends for protection during transit
and storage. Type of paint shall be as agreed upon with the company.
7.4
Both ends of all bends shall be suitably protected to avoid any damage during
transit by means of metallic or high impact plastic bevel protectors.
7.5
Package shall be marked legibly with suitable marking ink to indicate the following:
a)
Order Number
b)
Package Number
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8.0
c)
Manufacturers Name
d)
Size (Inches) and Wall thickness (mm)
e)
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
All documents shall be in English language
8.2
At the time of bidding, bidder shall submit the following documents:
8.3
a)
Reference list of previous supplies of bends of similar specifications.
b)
Brief description of manufacturing including heat treatment and quality

control facilities of the Manufacturers Works.
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)
Sequence of Operation
b)
Induction forming process including bending temperature, temperature

control, bending Rate , cooling rate and cooling procedure.
c)
Temperature measurement and calibration.
d)
Post bend heat treatment procedure including temperature and time.
e)
Dimensional control procedure.
f)
Pipe material used for bend manufacture
g)
NDT procedures
h)
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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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
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.
8.5
Prior to shipment, the Manufacturer shall submit test certificates as listed in section
6.0 of this specification.
9.0
BEND MANUFACTURING PROCEDURE QUALIFICATION
9.1
Prior to start of production bending, Manufacturer shall demonstrate the suitability

of the proposed manufacturing procedures for producing pipe bends including the
post-bending heat cycle, that meet the requirements of this specification, by
mechanically testing additional bend(s) (test bends). The bending procedure shall
be qualified in the presence of company representative.
9.2
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.
9.3
Inspection and Testing of Bends
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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FOR
FLOW TEE (BARRED TEE)
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CONTENTS
Sl. No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS & REQUIREMENTS
4.0
MANUFACTURE QUALIFICATION AND PRODUCTION TESTING
5.0
6.0
COATING / PAINTING
7.0
MATERIAL TESTING AND TRACEABILITY
8.0
PREPARATION FOR SHIPMENT
9.0
MARKING
10.0
VENDOR DATA REQUIREMENT
11.0
DESIGN OF BARRED TEE
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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
following codes, standards and specifications:
ASME B 31.8
Gas Transmission and Distribution

Piping System
ASME B16.9
Factory made Wrought Steel Butt

Welding Fittings
ASTM A370
Mechanical testing of steel products
ASTM E 92
Standard test method for Vickers

Hardness of metallic materials
ASTM E 709
Standard guide for Magnetic particle

examination
ASNT-SNT-TC-1A
American society of Non-destructive

testing
API 5L
MSS-SP-75
Specification for High Test Wrought

Welding Fittings
ISO 9000
Quality Management and Quality

Assurance Standards
ISO 9001
Quality Systems Model for quality

assurance in design, development,
production, installation and servicing
EN 10204
Metallic products types of inspection

documents
ISO 12094
Welded Steel tubes for pressure

purposes ultrasonic testing for the
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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.
3.2
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.
3.3
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.
3.4
The Tees shall meet or exceed the strength requirements of the matching
pipe as calculated by ASME B 31.8.
3.5
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.
3.6
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
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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
Vendor shall check & confirm the number of bars (as stated in Appendix-A)
required for Tees.
3.8
All pipeline Tees shall be suitable for passage of instrumented inspection

tools in either direction.
3.9
Fully killed carbon steel shall be used.
3.10
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.
CE =
C+
Mn
Cr + Mo + V
-------- + --------------------6
5
Ni + Cu
--------------15
3.11
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.
3.12
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.
3.13
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.
3.14
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.
3.15
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.
3.16
The fittings shall be heat treated by normalizing, quenching and tempering

to achieve the same strength of line pipe.
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4.0
3.17
Fittings shall not be machined from bar stock or solid forged billets.
3.18
Tees shall be supplied in normalized, normalized and tempered or quenched

and tempered condition.
3.19
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.
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.
5.0
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.
4.3.2
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.
4.3.3
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.

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
8.0
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.
7.2
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.
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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FOR
SCRAPER TRAPS
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DOCUMENT NO.
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CONTENTS
Sl. No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
5.0
6.0
TEST CERTIFICATES
7.0
8.0
GUARANTEE
9.0
SPARES
10.0
DOCUMENTATION
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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
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
Power Piping
ASME B 31.3
Process Piping
ASME B 31.8
Gas Transmission and Distribution

Piping System
ASME B 16.5
Steel Pipe Flanges and Flanges Fittings
ASME B16.9
Factory made Wrought Steel Butt

Welding Fittings
ASME B 16.11
Forged Steel Fittings, Socket-Welding

and threaded
ASME B 16.25
Butt-Welding Ends
ASTM A 105
Forging, Carbon Steel for Piping

components
ASTM A 181
Forging, Carbon Steel for general

purpose piping
ASTM A 216
Carbon Steel Castings suitable for

Fusion Welding for High temperature
Service
ASTM A 234
Piping Fitting of Wrought Carbon Steel

and Alloy Steel for moderated and
Elevated Temperatures
ASTM A370
Mechanical testing of steel products
ASTM A 20
ASTM A 516
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 106
Carbon steel seamless pipe for high

temperature service
ASTM A 193
Alloy steel and stainless steel bolting

materials for high temperature
ASTM A 194
Carbon and alloy steel nuts for bolts for

high pressure or temperature
ASME Sec-V, VIII and IX
Boiler and Pressure Vessels Codes
API 1104
Specification for Welding Pipeline and

Related Facilities
API 5L
MSS-SP-6
Standard Finishes for Contact Faces of

Pipe Flanges and Connecting End
Flanges of Valves and Fittings
MSS-SP-44

Welding Fittings
MSS-SP-75

Welding Fittings
MSS-SP-97
Integrally Reinforced Forged Branch

Outlet Fittings Socket Welding Threaded
and Butt Welding Ends
SSPC-VIS-1
Steel Structure Painting Council
ISO 10474
Steel and Steel Structures Inspection

documents
ISO 9000
Quality Management and Quality

Assurance Standards
ISO 9001
ISO 9002

assurance in design, development,
production, installation and servicing
assurance in production, installation and
servicing
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.
3.2
3.3

CE =
3.4
Mn
Cr + Mo + V
-------- + --------------------6
5
C+
Ni + Cu
--------------15
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
TEST
TEMPERATURE
BASE METAL AND

WELD
(-) 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.
3.6
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
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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DOCUMENT NO.
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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
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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.
c)
The location & orientation of all nozzle connections shall be submitted

for purchaser's approval before manufacturing.
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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NEW DELHI

SCRAPER TRAPS
DOCUMENT NO.
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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.
GAIL (INDIA) LTD
NEW DELHI

SCRAPER TRAPS
DOCUMENT NO.
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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

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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SCRAPER TRAPS
DOCUMENT NO.
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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
100% RT and UT
Nozzle to shell joint
100% UT and MPT
Attachments welds and lifting lug welds :
100% MPT and PT
All mating clamp and machined surfaces,

Door hinges attachment of end closure :
100% MPT or PT
Pig Trap barrel / Body material
100% Ultrasonic
Seam
100% RT scan
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
GAIL (INDIA) LTD
NEW DELHI
PROCEDURE
ASME Sect. V. Article 5 & 23

SCRAPER TRAPS
ACCEPTANCE CRITERIA
ASME Sect. VIII, Div. 3, Art.
AM 203.2(c)
ASTM A 578, Level I Cracks
DOCUMENT NO.
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Shell & Welding Ends

welds
Magnetic Particle
5.2
6.0

Dye Penetrant
Radiography
Not Allowed
ASME Sect. VIII, Div. 1, App.
12
6
6
ASME Sect. VIIII, Div. 1, Art.
UW51
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.
TEST 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.
b)
Hydrostatic test certificates.
c)
Test reports on radiography, ultrasonic inspection and magnetic particle

examination.
d)
Test reports on heat treatment carried out, if any.
The certificate shall be considered valid only when signed by purchasers

representative.
7.0

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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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)
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.
7.3
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.
7.4
All components shall securely anchor to the skid and package supports.
7.5
All opening, flange facings, etc., shall be sealed with waterproof coverings
for shipping. Threaded coupling shall be provided with steel plugs.
7.6
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.
7.7
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.
7.8
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.
7.9
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.
7.10
Only those traps, which have been inspected and certified by the
purchasers inspector shall be supplied.
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DOCUMENT NO.
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8.0
GUARANTEE:
8.1
9.0
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.
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.
9.2
Manufacturer shall furnish separately a list of recommended spares and

accessories required for two years of normal operation and maintenance of
Scraper Traps.
10.0 DOCUMENTATION:
10.1
Manufacturer shall furnish the following documents at the time of bidding:-
(a)
Outline General Arrangement Drawings of the equipment
(b)
Completed data Sheets
(c)
Confirmation of scope of supply, including detailed material and painting

specifications
(d)
Thickness of major and minor barrel
(e)
Vessel weight data, Erection weight, Operational weight, Maximum weight
(f)
Materials of Construction
(g)
Proposed manufacturing/delivery schedule
(h)
Proposed Quality Assurance/Safety Plan
(i)
Proposed Surface Treatment
(j)
Typical Inspection and Test Plan
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(k)
Table of Compliance
(l)
Catalogue of End Closure
(m)
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)
Design calculations according to the relevant codes for the body

including branch connections and quick end closures
b)
Support Assembly Drawing
c)
Trap assembly, Closure assembly and sectional drawings showing all

parts with materials and dimensions
d)
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.
10.4
Prior to shipment, the manufacturer shall submit one reproducible and six
10.5
a)
Test certificate as listed in clause 6.0 of this specification.
b)
Manual for installation, erection instructions, maintenance and

operations instruction.
All documents shall be in English Language.
GAIL (INDIA) LTD

NEW DELHI

SCRAPER TRAPS
DOCUMENT NO.
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FOR
PIG SIGNALERS
GAIL (INDIA) LTD

NEW DELHI

PIG SIGNALERS
DOCUMENT NO.
S-04-02-018
REV-0
Page 1 of 6
CONTENTS
Sl.No.
Description
1.0
SCOPE
2.0
MATERIALS
3.0
DESIGN AND CONSTRUCTION REQUIREMENTS
4.0
5.0
TEST CERTIFICATES
6.0
7.0
GUARANTEE
8.0
9.0
DOCUMENTATION
GAIL (INDIA) LTD

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PIG SIGNALERS
DOCUMENT NO.
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Page 2 of 6
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.
2.2
2.3

CE =
2.4
3.0
C+
Mn
Cr + Mo + V
-------- + --------------------6
5
Ni + Cu
--------------15
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.
DESIGN AND CONSTRUCTION:

3.1
Pig signallers shall be bi-directional type having pivot-less tumbler

mechanism and laminated trigger blades.
3.2
Pig signallers shall be designed to meet the requirements of pipeline

material, diameter, wall thickness & service conditions indicated in the data
sheet.
3.3
Design of pig signallers shall be such that any possibility of signaler being
operated by line pressure is eliminated.
3.4
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.
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NEW DELHI

PIG SIGNALERS
DOCUMENT NO.
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Page 3 of 6
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.
3.6
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
4.0
5.0
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
3.8
Whenever specified in the data sheet, pig signallers shall be provided with
extension, suitable for installation on underground pipeline.

4.1
Manufacturer shall perform all inspection and tests required to supply the
signallers as per the requirements of this specification.
4.2
All pig signallers shall be visually inspected.
4.3
Chemical composition & mechanical properties including hardness shall be

checked for each heat of steel used.
4.4
All welds shall be non-destructively examined.
4.5
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.
4.6
Hydrostatic test shall be conducted at a pressure equal to 1.5 times the

design pressure. Hydro test duration shall be 15 Minutes.
4.7
Manufacturers shall perform functional tests to establish satisfactory

performance of both manual and electrical indications.
TEST CERTIFICATES:
GAIL (INDIA) LTD

NEW DELHI

PIG SIGNALERS
DOCUMENT NO.
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Page 4 of 6
6.0
5.1
Manufacturer shall supply the test certificates for material compliance as per
the relevant Material Standards.
5.2
Certificate for hydrostatic test and functional test.
5.3
Test reports on heat treatment carried out, if any.

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.
6.2
A corrosion resistant metal tag shall be permanently attached with each

unit, with the following marking:i)
ii)
iii)
iv)
6.3
7.0
8.0
Manufacturers name
Suitable for installation in_______mm dia. pipeline
ANSI Rating
Tag No.
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.
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.
7.2
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.
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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PIG SIGNALERS
DOCUMENT NO.
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REV-0
Page 5 of 6
8.2
9.0
Manufacturer shall furnish separately a list of recommended spares and

accessories required for two years of normal operation and maintenance of
Pig Signallers.
DOCUMENTATION:
9.1
9.2
At the time of bidding, bidder shall submit the following documents:a)
General Arrangement drawing with overall dimensions.
b)
Clause wise list of deviation from this specification, if any.
c)
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.
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)
Fabrication drawings/ sectional arrangement drawings showing all

parts with reference numbers and material specification.
b)
Assembly drawing with overall dimension.
c)
Welding and testing procedure.
d)
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.
9.4
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.
GAIL (INDIA) LTD

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PIG SIGNALERS
DOCUMENT NO.
S-04-02-018
REV-0
Page 6 of 6
FOR
INSULATING JOINTS
GAIL (INDIA) LTD

NEW DELHI

INSULATING JOINTS
DOCUMENT NO.
S-04-02-019
REV-0
Page 1 of 9
CONTENTS
Sl. No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
5.0
6.0
TEST CERTIFICATES
7.0
8.0
GUARANTEE
9.0
DOCUMENTATION
GAIL (INDIA) LTD

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INSULATING JOINTS
DOCUMENT NO.
S-04-02-019
REV-0
Page 2 of 9
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.
2.0
REFERENCE DOCUMENTS
2.1
Reference has been made in this specification to the latest edition of
following Codes, Standards and Specifications.
3.0
the
a)
ASME B 31.8 (Gas Transmission & Distribution piping System)
b)
ASTM A 370 (Mechanical testing of Steel Product)
c)
ANSI B 16.25 (Butt Welding Ends)
d)
ASME Section Boiler & pressure Vessel Code viii & ix
e)
API 1104 (Standard for welding pipelines and related facilities)
f)
SSPC-VIS-1 (Steel Structures painting Council Visual Standard)
g)
MSS-SP-53 (Quality standard for steel castings and forgings for valves
flanges and fittings and other piping components - magnetic particle
examination method)
h)
MSS-SP-75 (Specification for high test wrought welding fittings)
i)
NACE RP 0286 (Standard for electrical isolation of cathodically protected

pipelines)
2.2
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.
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.
3.2
Insulating joints, which are subject to field welding by purchaser, shall have
carbon equivalent (CE) not exceeding 0.45 based on check analysis for each
heat of steel calculated according to the following formula:
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INSULATING JOINTS
DOCUMENT NO.
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REV-0
Page 3 of 9
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.
3.4
Carbon steel used for the manufacture shall be fully killed
3.5
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.
3.6
Insulation material shall be minimum 20 mm thick and shall comply section

5, NACE RP 0286.
4.0
DESIGN & CONSTRUCTION REQUIREMENTS
4.1
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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INSULATING JOINTS
DOCUMENT NO.
S-04-02-019
REV-0
Page 4 of 9
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.
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INSULATING JOINTS
DOCUMENT NO.
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REV-0
Page 5 of 9
4.1.14 Out of roundness measured at the root face of the welding ends shall not
be more than 0.5% of the specified inside diameter.
4.2
Electrical
4.2.1 The average dielectric strength of the insulating joint shall be minimum 15
kilo Volts.
4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either
side of the insulating joint for connecting 10 mm2 and 50 mm2 cables for
measurement/ shorting purposes. Cleats shall be attached to the insulating
joint by welding.
5.0

5.1
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.
b)
All finished weld ends shall be 100% ultrasonically tested for

lamination type defects for a distance of 50mm from the ends. Any
lamination larger than 6.35 mm shall not be acceptable.
c)
All forgings shall be wet magnetic particle inspected on 100% of

forged surfaces. Method and acceptance shall comply with MSS-SP53.
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INSULATING JOINTS
DOCUMENT NO.
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REV-0
Page 6 of 9
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
5.2
6.0
a)
Insulation resistance of each insulating joint shall be at least 25 mega

ohms when checked with 500-1000 V DC.
b)
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.
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.
TEST CERTIFICATES
6.1
Manufacturer shall
Representative.
submit
following
certificates
to
Purchaser's
a)
Test certificates relevant to the chemical analysis and mechanical

properties including hardness of the materials used for construction
of insulating joint as per this specification and relevant standards.
b)
Test reports on non-destructive testing.
c)
Test certificates for hydrostatic and air tests.
d)
Test certificate for electrical test.
e)
Test report on vacuum test.
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INSULATING JOINTS
DOCUMENT NO.
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REV-0
Page 7 of 9
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.
7.2
Insulating joints shall be marked with indelible paint with the following
data:a.
b.
c.
d.
e.
f.
g.
h.
8.0
9.0
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
7.3
Insulating joints shall be suitably protected to avoid any damage during

transit. Metallic bevel protectors shall be provided to weld ends.
7.4
Only those insulating joints which have been inspected and certified by
Purchaser shall be shipped.
GUARANTEE
8.1
The manufacturer shall guarantee that the materials used comply with the
8.2
Manufacturer shall replace or repair insulating joints found defective due to

inadequate engineering or quality of material.
8.3
Manufacturer shall replace the insulating joint without delay if the defect or
malfunctioning can not be eliminated.
8.4
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.
DOCUMENTATION
9.1
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INSULATING JOINTS
DOCUMENT NO.
S-04-02-019
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Page 8 of 9
9.2
9.3
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)
Reference lists of previous supplies of insulating joint of similar

specification.
c)
Clause wise list of deviation from this specification, if any.
Within three weeks of placement of order, the Manufacturer shall submit

four copies of the following drawings, documents and specifications for
approval.
a)
Fabrication drawings and relevant calculations for pressure containing

parts.
b)
Welding procedure and method of manufacture for all phases of

manufacture.
c)
Quality Assurance Plan (QAP)
d)
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.
9.5
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.
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INSULATING JOINTS
DOCUMENT NO.
S-04-02-019
REV-0
Page 9 of 9
GAIL (INDIA) LTD

NEW DELHI
STANDARD SPECIFICATION FOR CASING

INSULATORS AND END SEALS
SPECIFICATION
S 04 02 - 020
REV-0
Page 1 of 8
GAIL (INDIA) LTD

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SPECIFICATION
S 04 02 - 020
REV-0
Page 2 of 8
PART A
1.0
CASING INSULATORS
SCOPE
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
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SPECIFICATION
S 04 02 - 020
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Page 3 of 8
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

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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SPECIFICATION
S 04 02 - 020
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Page 4 of 8
PART - B
CASING END SEALS
SCOPE
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
Minimum Value
Test Method
Tensile strength
2200 psi
ASTM D 638
Ultimate Elongation
400 %
ASTM D 638
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SPECIFICATION
S 04 02 - 020
REV-0
Page 5 of 8
Heat Shock
b)
No Visual Cracks,
Flow or Drips at 250C,
4 hours
ASTM D 2671
Propertv
Minimum Value
Test Method
Ring and Ball

Softening Point
90C
ASTM E 28
Lap Shear
60C - 25 psi
23C - 250 psi
(2 inchlmin.)
ASTM D 1002
Property
Minimum Value
Test Method
Peel strength
(To casing and carrier
pipe and closure patch)
5 pli
(1 0 inchlmin.)
ASTM D 1000
Adhesive
c)
System (As Applied)
5 .O

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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SPECIFICATION
S 04 02 - 020
REV-0
Page 6 of 8
PART - C
SUPPLEMENTARY REQUIREMENTS
1.0
The manufacturer shall replace, at no extra cost, any material not conforming to the
material and performance requirements of this specification.
2.0
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.
3.0
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.
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SPECIFICATION
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Page 7 of 8
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SPECIFICATION
S 04 02 - 020
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Page 8 of 8
FOR
FIELD JOINT COATING
(ONSHORE PIPELINES)
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STANDARD SPECIFICATION FOR FIELD

JOINT COATING (ONSHORE PIPEINE)
SPECIFICATION
S-04-02-021
REV-0
Page 1 of 15
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NEW DELHI

SPECIFICATION
S-04-02-021
REV-0
Page 2 of 15
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SPECIFICATION
S-04-02-021
REV-0
Page 3 of 15
1.0
SCOPE
1.1
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.
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.
b)
ASTM D-257
Standard Test Methods for D-C Resistance or

conductance of insulating materials.
c)
ASTM D-570
Standard Method of Test for Water Absorption of

Plastics.
d)
e)
IS0 8502 3
ISO 8503 1
GAIL (INDIA) LTD

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: 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)
:
Part 1: Specification and definitions for IS0 surface

profile comparator for the assessment of abrasive
blast cleaned surfaces.

SPECIFICATION
S-04-02-021
REV-0
Page 4 of 15
f)
ISO 8503 4
Part 4: Methods for calibration of IS0 surface profile

comparator and for the determination of surface
profile Stylus instrument procedure.
g)
SIS 055900
Pictorial Surface Preparation Standard for Painting

Steel Surfaces.
h)
SSPC-SP 1
Steel Structure Painting Council
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
3.1
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.
3.1.1 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)
GAIL (INDIA) LTD

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Thickness (mm)
Average
2.0
2.4
On Pipe Body
Min.
1.8
2.2

On Weld Bead
(Min.)
1.6
2.0
SPECIFICATION
S-04-02-021
REV-0
Page 5 of 15
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.
PROPERTIES
UNIT
REQUIREMENT
TEST METHOD
Tensile Strength @ + 25 0C
N / mm2
12
DIN EN 12068
b.
Ultimate Elongation @ + 25 0C
250 0C
DIN EN 12068
c.
Dielectric Withstand with 1000 Volts/Sec
KV
30
ASTM D 149
Water absorption @ +25 0C for 24 Hours
0.05
ASTM D 570
e.
Volume Resistivity @ +25 0C
Ohm-cm
1015
ASTM D 257
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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)
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
b)
Peel Strength shall be as follows :

Peel Strength
Inner to Inner
(+) Outer to
Inner
@ 23 0C
N/mm
Requirement for
Mechanical Resistance
Class C (minmum)
1.5
@ Tmax
N/mm
0.3
Outer to Outer
@ 23 0C
N/mm
1.5
@ Tmax
N/mm
0.3
@ 23 0C
N/mm
3.5
@ Tmax
N/mm
0.5
@ 23 0C
N/mm
3.5
@ Tmax
N/mm
0.5
To pipe surface
To Factory
Coating
Unit
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
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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Material qualification
Batch number
Date of manufacturing and date of expiry
3.4
Contractor shall ensure that the Manufacturer has carried out all quality control tests on
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.
3.5
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.
3.6
Contractor shall provide and maintain mobile facilities which contain all necessary
equipment and its spares for cleaning, coating, repairs, inspection and tests.
3.7
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)
Fully automatic full circle adjustable holiday detector with a visible and audible
signal system for inspection of coatings.
b)
Thickness gauge for measuring thickness.
c)
Contact type temperature recording thermometer (Digital Pyrometer with flat

probe type contact).
d)
Roughness profile measuring (Stylus) instrument
4.0
APPLICATION PROCEDURE
4.1
General
4.1.1 The application procedure shall be in accordance with manufacturer's instructions and
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)
Surface preparation, cleanliness, roughness profile and dust contamination
(ii)
Pre-heat temperature (as applicable)
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(iii)
Primer thickness
(iv)
As applied coating thickness
(v)
Holiday detection
(vi)
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.
(vii)
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.)
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
Visual Inspection
Visual inspection of the as applied coating shall be carried out on every joint, for the
following:
(i)
Mastic extrusion on either ends of the sleeve shall be examined
(ii)
There shall be no sign of punctures or pinholes or bend failure. The external

appearance of the sleeve shall be smooth, free of dimples, air entrapment or
void formation. 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.
(iii)
Weld bead profile shall be visible through the sleeve
(iv)
Visual indicator provided on the backing and the closure patch showing desired
heat is achieved.
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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
REPAIRS
6.1
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)
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.
6.2
Contractor shall replace all joint coating found or expected to be unacceptable as per
section 5.0 of this specification.
6.3
Contractor shall, at his own cost repair all areas where the coating has been removed
for testing by the Company.
6.4
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.
6.5
Company shall be entitled to check the coating on buried pipelines or parts of pipelines
with equipment such as the "Pearson Meter" and the resistance meter. If coating
defects are established, the Contractor shall be responsible for excavation at such
points, repairing the coating, spark testing and backfilling the excavations without extra
charge.
7.0
DOCUMENTATION
7.1
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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b.
c.
7.2
Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish
the following documents:
a.
b.
c.
7.3
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.
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.
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FOR
CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
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1.0
SCOPE
1.1
This specification covers the minimum requirements for the materials, application,
inspection, handling and other activities for external concrete weight coating of
pipelines.
1.2
and documents included in the CONTRACT between Company and Contractor.
1.3
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.
1.4
Unless otherwise specified, all sections of this specification shall apply to all the
specification referred in this specification.
2.0
REFERENCE DOCUMENTS
2.1
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
Indian Standard Specification for Ordinary

Portland Cement.
IS-383
Indian Standard Specification for Coarse And Fine

Aggregates From Natural Sources For Concrete.
IS-2386 (Parts-I
Indian Standard Methods of Test for Aggregates for

Concrete. thru' VIII)
IS-8 1 12
Indian Standard Specification for High Strength

Ordinary Portland Cement.
ASTM A-82
Specification for Steel Wire, Plain, for concrete

Reinforcement.
ASTM A-1 85
Specification for Steel Welded Wire Fabric, Plain, for

Concrete Reinforcement
ASTM A-64 1
Specification for Zinc Coated (Galvanized) Carbon

Steel Wire.
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ASTM C-39
Test Method for Compressive strength of cylindrical

concrete specimens.
ASTM C-138
Test Method for Unit weight, Yield and Air Content of

Concrete.
ASTM C-309
Specification for Liquid Membrane Forming

Compounds for Curing Concrete.
ASTM C-642
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
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
MEASUREMENTS AND LOGGING
7.1
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.
7.2
The following shall be subject to measurement and logging for each pipe length :
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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
b)
(F)
(M)
(L)
(BW)
(OD) / (WT)
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)
(C)
(CT)
(CW)
(A)
(DCC)
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
No concrete placing shall be allowed before items 1 through 10 listed at clause 7.2,
have been logged.
8.0
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.
8.3
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.
8.4
The mix so determined, shall then be used for sampling of concrete to be submitted to
compressive strength tests as per ASTM C39.
8.5
Frequency of sampling for tests for density and compressive strength of concrete shall
be as follows:
Quantitv" of Concrete in the Work (m3)
Number of Samples
Upto 25
26 to 50
5 1 and above
3
4
4
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
APPLICATION OF REINFORCEMENT AND CONCRETE COATING
9.1
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.
9.2
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
Curing
9.6.1
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.
10.2
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.
11.0 WEIGHING
11.1
The test specimen shall be selected at equal intervals during the course of production.
11.2
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.
11.3
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.
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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.
12.2
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.
12.3
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.
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.
13.2
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.
13.3
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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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.
14.2
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.
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.
15.2
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.
15.3
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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15.4
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.
15.5
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.
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FOR
REPAIR OF POLYETHYLENE COATING
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STANDARD SPECIFICATION FOR REPAIR

OF POLYETHYLENE COATING
SPECIFICATION
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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
MATERIAL AND EQUIPMENT
2.1
The repair material shall be as under:

a)
Repair Patch: radiation cross-linked polyolefin with semi-crystalline

thermoplastic adhesive (PERP80 of make Covalence Raychem or equivalent).
b)
Filler Mastic: PERPFILLER of make Covalence Raychem or equivalent.
c)
PERP melt stick of make Covalence Raychem or equivalent
2.2
The repair material shall be certified by DIN to meet the requirements of EN12068
Stress Class CHT 80
2.3
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.
2.4
Materials shall be stored in sheltered storages in the manufacturer's original packing

away from direct sunlight and in accordance with manufacturer's instructions.
2.5
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
INSPECTION AND TEST
4.1
A visual inspection shall be carried out for the following:
4.2
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.
Holiday lnspection
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The holiday detector used shall be checked and calibrated daily with an accurate D.C.
Voltmeter. The detector electrode shall be in direct contact with the surface of coating
to be inspected.
The entire surface of the repaired section shall be inspected by means of a full circle
holiday detector approved by Owner set to a D.C. Voltage of at least 25 KV. Inspection
of repaired patch shall be conducted only after it has cooled below 500 C.
4.3
Procedure qualification shall be carried out for repair patch. The value for peel strength
to pipe surface and to factory coating carried out as per EN 12068 shall be 0.5 N/mm
minimum at 60C.
4.4
All repaired joint shall be approved by the Owner.
5.0
DOCUMENTATION
5.1
Prior to procurement of coating repair materials, Contractor shall furnish four copies of,
but not limited to, the following for qualification of the Manufacturer and material:
i)
Complete descriptive technical catalogs describing the materials offered along with
samples of repair coating materials, its properties and installation instruction as
applicable specifically to the project.
ii)
Test certificate and results of previously conducted tests from independent inspection
agency, for properties listed in Para 4.3 of this specification.
iii)
Reference list of previous supplies of the similar material indicating the project details
such as diameter, quantity, service conditions, 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.
5.2
5.3
Prior to shipment of materials from the Manufacturer's works, Contractor shall furnish
six copies of the following:
i)
Test certificates for each batch of materials,
ii)
Specific installation instruction with pictorial illustrations
iii)
Specific storage and handling instructions.
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SPECIFICATION
FOR
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STANDARD SPECIFICATION FOR QUICK

OPENING END CLOSURE
SPECIFICATION
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CONTENTS
SI.No.
Description
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
MATERIALS
4.0
5.0
6.0
TEST CERTIFICATES
7.0
8.0
GUARANTEE
9.0
SPARES
10.0
DOCUMENTATION
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SCOPE
This specification covers the minimum requirements for design, manufacture, testing and
supply of quick opening end closures to be installed at various blow-down points/ lines
handling non-sour hydro carbons in gaseous phase.
1.0
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 specifications:
a)
ASME B 31.8
Gas Transmission and Distribution Piping System
b)
ASME B 16.25
Butt - Welding Ends
c)
ASME Sec. VIII
Boiler and Pressure Vessels Code- Rules for the

Construction of Pressure vessels
d)
ASME Sec. IX
Boiler and Pressure Vessels Code-Welding and brazing

qualifications.
e)
API 6H
Specification on End closures, Connectors

and Swivels
f)
API 1104
Specification for Welding Pipeline and Related

Facilities
g)
SSPC-VIS-1
Steel Structures Painting Council
In case of conflict between the requirement of this specification and the requirements of
above referred documents, the requirements of this specification shall govern.
3.0 MATERIALS
3.1 Carbon steel material used in the manufacture of pressure containing parts of quick
opening enclosure shall be fully killed. In addition, the material shall also meet the
requirements specified herein.
The minimum SMYS of the material of pressure containing part of the closure shall be
35,000 psi.
Other components shall be as per Manufacturers Standard. However, all the materials
used shall be suitable for the service Conditions indicated in the Data Sheets, which will
be subject to approval by Purchaser.
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3.2 Material of the ends to be field welded by Purchaser shall have carbon equivalent not
more than 0.45 based on check analysis, for each heat of steel used, calculated as per
the following formula:
Mn
CE = C + ------ +
6
Cr+Mo+V Ni+Cu
---------------- + ----------5
15
3.3 For quick opening end closures specified to be used for Gas service and LPG service,
Charpy V-notch test shall be conducted at 00C on each heat of carbon steel material used
in manufacture of quick opening end closures. Test procedure shall conform to ASTM A
370. The 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 22 Joules.
When Low Temperature Carbon Steel (LTCS) materials are specified in Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material
standard shall be complied with.
3.4 For quick opening end closures specified to be used for Gas service and LPG service,
hardness test shall be carried out as per ASTM A 370 for each heat of steel used in the
manufacture of pressure containing parts of traps. A full thickness cross section shall be
taken for this purpose and the maximum hardness of base metal, weld metal and HAZ of
all the pressure containing parts shall not exceed 248 HVlo.
4.0 DESIGN AND CONSTRUCTION
4.1 End closure shall be designed in accordance with the provisions of ASME B 31.8 and
ASME Sec. VIII Division 1. Design factor and corrosion factor shall be as indicated in the
data sheet.
4.2 Diameter, thickness, material, ANSI rating of the pipeline with which the end closure to
be welded shall be as indicated in the Data Sheets. End closure supplied shall be suitable
for the same.
4.3 The quick opening end closure shall be of clamp ring/ band lock type or equivalent design
and shall consists of a safety pressure release system allowing the opening only when
there is no pressure in the trap. End closure shall be hand operated by a single lever
operation and operable by one operator. Screwed type or plug -in type of end closures
are not permitted.
4.4 End closure shall be suitable for installation in vertical position at an elevation of 2.0
meters above ground level.
4.5 The handing device shall be attached to the welding end hub, which shall be suitable for
such attachment.
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4.6 End closure shall be provided with a butt-welding end for direct welding with the pipeline.
The weld end shall be prepared in accordance with ASME B 31.8.
4.7 All welds shall be made by welders and welding procedures qualified in accordance with
the provisions of ASME Sec. IX. The procedure qualification shall also include impact test
and hardness test as per clause 3.3 and 3.4 of this specification and shall meet the
4.8 Completed assembly shall be stress relieved as per the provisions of the design codes.
4.9 The tolerance on internal diameter end out of roundness shall be as per connected pipe
specifications indicated in the Data Sheet.
4.10 When closed, the closure shall provide a positive seal without any leakage. Gaskets or
seals when provided for this purpose shall be self sealing and suitable for the service
condition indicated in Annexure-I & Data Sheets.
5.0 INSPECTION AND TESTS
5.1 Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, standards and specifications, prior to shipment at
his Works. Such inspection shall be, but not limited to, the following:
5.1.1 All closures shall be visually inspected. The internal and external surfaces shall be free
from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly
cleaned and free from dirt, rust and scales.
5.1.2Chemical composition and mechanical properties shall be checked as per relevant
5.1.3Dimensional check shall be carried out as per the approved drawings.
5.1.4 Hydrostatic test shall be conducted for all end closures complete in all respects, at a
pressure equal to 1.25 /1.4 times the design pressure for liquid / gas service as
indicated in data sheet. Test duration shall be 15 minutes.
5.1.5 All butt welds shall be 100% radiographically inspected. Procedure and acceptance
criteria shall be as per API 1104.
5.1.6 Welds, which cannot be radiographically inspected, shall be inspected by ultrasonic or
magnetic particle methods. Procedure and acceptance criteria shall be as per ASME Sec.
VIII, Appendix-U and Appendix VI respectively.
5.1.7 All finished wrought weld ends shall be ultrasonically inspected for lamination type
defects for a distance of 50 mm from the end. Any lamination larger than 6.35 mm
shall not be acceptable.
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5.1.8 A minimum of two Closing and opening cycles shall be performed and correct operation
of both quick opening and safety system shall be established.
5.2
Company inspector reserves the right to perform inspection and witness tests including
hydrostatic test, 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.
Only those closures, which have been inspected and certified by Companys
Representative, shall be shipped.
Inspection and tests performed / witnessed by Company's Inspector shall in no way
relieve the Manufacturer's obligation to perform the required inspection and tests.
6.0
TEST CERTIFICATES
a. Test Certificates relevant to chemical and mechanical properties of the material used
as per the relevant standards.
b. Hydrostatic test certificates.
c. Report on Non-Destructive examination.
d. Certificate of satisfactory performance of end closure as per Clause 5.1.8.
7.0
7.1
After all inspection and tests required have been carried out, the exterior surface of
Quick Opening End Closures 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.
7.2
Marking shall be done on a stainless steel plate and affixed to the body permanently.
Marking shall include the following:
a. Manufacturer's Name
b. Suitable for --------- Dia x ---------- Thick Pipeline.
c. ANSI Rating
d. Tag Number
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7.3
Before shipment, closures shall be properly packed against damage during

transportation.
Suitable protection shall be provided for the weld ends.
8.0
GUARANTEE
8.1
Manufacturer shall guarantee that the closure along with the davits is in compliance
with the requirements of this specification for material and workmanship. Manufacturer
shall replace or repair all parts which should result defective due to inadequate
engineering of quality of material or workmanship. In case the defect cannot be
eliminated, Manufacturer shall replace the closure without any delay. Any defects
occurring within the time period specified elsewhere shall be required making all
necessary modifications and repair of defective parts free of charge to the purchaser.
9.0
SPARES
9.1.1
Manufacturer shall furnish list of recommended spares and accessories for Quick
Opening End Closures required during start-up and commissioning and supply of such
spares shall be included in the price quoted by Manufacturer.
9.1.2
Manufacturer shall furnish list of recommended spares and accessories required for two
years of normal operation and maintenance of Quick Opening End Closures and price
for such spares shall be quoted separately.
10.0
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.
10.1

a) General arrangement drawing of end closure with overall dimensions and crosssectional drawings.
b) Clause wise list of deviations from this specification, if any.
c) Reference list of similar previous supplies. Reference list of similar supplies of Quick
Opening End
Closures shall be furnished including project, Year of supply, Client,
Size, Rating and Service for the last five years.
d) Quality Control Manual and Quality Control Plan.
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e) List of recommended spares and accessories required during start-up and

commissioning.
f) List of recommended spares and accessories required for 2 years of normal
operation and maintenance.
10.2
Within three weeks of placement of order, the Manufacturer shall submit the following
drawings,
documents and specifications for approval:
a. Design calculations according to relevant codes for the end closure.
b. Closure assembly and sectional drawings showing all parts with materials and
dimensions.
c. Welding procedure and method of manufacture.
Once the above-mentioned documents have been approved by the Company, any
change in design, material and method of manufacture shall be notified to the
Company, whose approval in writing of all changes shall be obtained before the
closures are manufactured.
10.5
Within four weeks from the approval date, Manufacturer shall submit the approved
drawings, documents and specifications listed in Clause 9.2 of above.
10.6
Prior to shipment, the Manufacturer shall submit the following:

a. Test certificates as listed in Clause 6.0 of this specification.
b. Manual for installation, erection instructions, maintenance and operation instructions.
10.7
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SPECIFICATION
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PIPELINE RIVER CROSSINGS USING
DIRECTIONAL DRILLING METHOD
GAIL (INDIA) LTD

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PIPELINE RIVER CROSSING USING
DOCUMENT NO.
S-04-02-025
REV-0
Page 1 of 15
CONTENTS
1.0
SCOPE
2.0
DESIGN AND ENGINEERING
3.0
CONSTRUCTION
4.0
DOCUMENTATION
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DOCUMENT NO.
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Page 2 of 15
1.0
SCOPE:
1.1
This specification covers the minimum requirements for various activities to be

performed by the CONTRACTOR for the engineering and construction of pipeline
river crossings using directional drilling method.
1.2
This specification shall be read in conjunction with the requirements all

specifications and documents included in the CONTRACT between COMPANY and
CONTRACTOR.
1.3
CONTRACTOR shall, execute the work in compliance with laws, by-laws,

ordinances and regulations. CONTRACTOR shall provide all services, labour,
inclusive of supervision thereof, supply of all materials, (excluding "COMPANY
supplied Materials ") equipment, appliances.
1.4
CONTRACTOR shall take full responsibility for the stability and safety of all
operations and methods involved in the work.
1.5
CONTRACTOR shall be deemed to have inspected and examined the work area and
its surroundings and to have satisfied himself as far as practicable with sub-surface
conditions, hydrological and climatic conditions, the extent and nature of the work
and materials necessary for the completion of the work, and the means of access
to the work area.
1.6
CONTRACTOR shall be deemed to have obtained all necessary information with

regard to risks, contingencies and all other circumstances, which may influence the
work.
1.7
CONTRACTOR shall, in connection with the work, provide and maintain at his own
costs all lights, guards, fencing, as necessary or directed by COMPANY.
1.8
For the purpose of this specification, the following definitions shall hold:
The words 'Shall' and 'Must' are mandatory.

The words 'Should, May and Will' are non- mandatory advisory, or
recommended.
2.0
DESIGN & ENGINEERING:
2.1
The minimum requirement of limits of each river crossing shall be as defined in the
drawings furnished by COMPANY. CONTRACTOR may change the limits slightly to
suit his equipment and installation technique, with prior written approval from
COMPANY.
Within the entire limits of crossing, as defined in the CONTRACT drawings, the
cover to top of corrosion coated pipe shall be at least 2.5 meters below the
"specified" minimum scour level profile for the river with normal soil, and at least
1.5 meters below the "specified" minimum scour level profile for the river with rock
sub-strata.
2.2
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2.3
The entry and exit points of the pipeline at ground level shall not come within the
limits of crossing as defined for individual river crossings.
2.4
Wherever the drilled length for a river crossing includes the crossings of other
obstacles such as roads, railroads, canals, streams, etc., the following minimum
requirements of cover to the pipe shall be satisfied:
For Road crossing
1.4 m from top of road to top of pipe
For Railroad crossing
1.7 m from base of rail to top of pipe
For canal / stream crossing
1.5 m from lowest bed level to top of

pipe
2.5
CONTRACTOR shall carry out calculations for determining the maximum

permissible overburden on pipe, to check that the empty pipeline is safe from
collapse at any point along the drilled crossing section. CONTRACTOR shall submit
these calculations to COMPANY for approval.
2.6
Pipeline Axis
As shown in the reference drawing at each crossing, the plane containing the pipe
axis shall be perpendicular to the horizontal plane. There shall be no bending of
longitudinal pipe axis at depths shallower than two meters below ground level.
2.7
Back-reamed Hole and Pipeline Interface

For each crossing, CONTRACTOR shall device a suitable combination of the
following:
Back-reamed hole diameter
Bentonite density
Pipeline submerged weight in Bentonite (and means to achieve that

weight)
In order to optimize the crossing design in terms of pipeline stresses and pull force
requirements. CONTRACTOR shall indicate what maximum shear stress in the
pipeline coating will result from his choice of above parameters and other design
characteristics described in this section.
CONTRACTOR shall furnish all calculations for COMPANY'S approval. If shear stress
on pipe coatings is, in the opinion of COMPANY, beyond the permissible limits,
CONTRACTOR shall revise his choice of parameters to reduce shear stress on pipe
coating to permissible values.
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2.8
CONTRACTOR shall determine the minimum allowable elastic bend radius for pipe
from the following considerations.
2.8.1 Pipeline maximum longitudinal stress during installation

Total maximum longitudinal stress in the pipeline due to tension and bending at
any location shall not exceed 90 % of the SMYS of the pipe material.
CONTRACTOR shall, in order to check this requirement, evaluate the maximum
tension forces to which the pipeline is subjected at any phase of its installation
during the pulling operation.
2.8.2 Pipeline maximum equivalent stress during final hydro test
After installation, the pipeline shall be hydrostatically tested to a minimum test
pressure equal to 1.4 times design pressure for gas pipeline and 1.25 times design
pressure for liquid pipeline. The combined equivalent stress in the pipeline due to
bending and test pressure shall not exceed 90 % of the SMYS of pipe material.
2.8.3 Pipeline maximum equivalent stress during service
Permissible values of pipeline maximum equivalent stress during service shall be
governed by the requirements of ASME B3 1.8/B3 1.4, as applicable.
2.8.4 The minimum allowable radius of curvature for the pipeline shall be the highest
value of the minimum pipeline elastic bend radius as computed from the
considerations outlined in clause 2.8.1 thru' 2.8.3 above after correction for drilling
inaccuracies or multiplication by the factor 1.85, whichever result in the highest
permissible value of minimum elastic bend radius.
2.8.5 CONTRACTOR shall submit all calculations for COMPANY'S approval.
2.9
Pipeline Configuration Along The Supported String Before Entry Point

For each crossing, CONTRACTOR shall determine the required pipeline
configuration in order to allow smooth pull in the crossing entry point and
admissible stress in the supported pipeline string. Pipeline combined stress shall
not exceed 90 % of the specified minimum yield strength for line pipe material.
CONTRACTOR shall furnish all calculations and specify the number of required
supports, description of the supports, their coordinates and capacity in metric tons.
CONTRACTOR shall also furnish a drawing of the launching ramp indicating the
pipeline configuration.
The distance between each roller shall also be specified and justified.
2.10
CONTRACTOR shall, based on results of design and engineering carried out by him,
prepare construction drawings for each river crossing and shall submit the same
for COMPANY'S approval. Construction drawings shall indicate the pipeline profile
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with levels furnished at sufficient intervals for proper control during construction.
Other relevant details viz. entry and exit angles, radii of bends, etc. shall also be
indicated.
CONTRACTOR shall also calculate the total length of pipeline required as well as
the maximum tension required on the pull head of the rig.
All construction works shall be carried out in accordance with the construction
drawings approved by COMPANY.
2.11
Before commencement of any field work, CONTRACTOR shall furnish for

COMPANY'S approval all design calculations as stipulated in clause Nos. 2.5, 2.7,
2.8, 2.9 and 2.10 above and all construction drawings. COMPANY shall inform
CONTRACTOR within 21 calendar days if any objection against the design requires
resubmission by CONTRACTOR.
3 .O CONSTRUCTION:
CONTRACTOR shall comply with all the conditions and requirements issued by
Authorities having jurisdiction in the area where the work is to be performed.
If no public road exists, CONTRACTOR shall arrange on his own for access to his
work area at no extra cost to COMPANY.
3.1
Installation Procedure
CONTRACTOR shall, before commencing any work at site, submit for COMPANY'S
approval a detailed installation procedure for each river crossing.
The installation procedure as a minimum shall include the following:
a)
Project Organization Chart

(This shall indicate CONTRACTOR'S organizational set-up at site and
manpower deployment)
b)
Preparation of Fabrication Yard and Launching Areas
c)
Details of Equipment
CONTRACTOR shall furnish the complete list of all equipment to the
deployed for preparation of pipe string and installation of crossing. Technical
characteristics and capacity of each equipment including instrumentation,
monitoring and control equipment shall be furnished in details.
d)
Pipeline String Preparation Details (hauling, stringing, welding, etc.)
e)
Pre-Installation Hydrostatic Test Procedure.
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f)
Method of Installation covering all steps of construction, viz. Rig up, Pilot
Hole, Back- reaming, Pulling, Rig Down, Backfilling.
g)
Calculations for Maximum Pulling Force on the rig and recommended

maximum pulling velocity.
h)
Final Hydrostatic Test Procedure after backfilling.
i)
Time Schedule for construction.
COMPANY shall inform CONTRACTOR within 21 calendar days if any objection

against the document and procedures described requires resubmission by
CONTRACTOR.
The time schedule shall be in accordance with overall time schedule for the
project.
Approval by COMPANY of the methods used by CONTRACTOR shall in no way
relieve CONTRACTOR from the sole responsibility for safe and satisfactory
installation of the crossing.
3.2
R.O.U. Preparation
CONTRACTOR shall clear and grade the length of ROU required for installation of
on land portion and drilled river crossing portion in his scope. CONTRACTOR shall
do such grading on Right of Use to provide access to the pipeline construction and
to ensure safe construction of pipeline.
CONTRACTOR shall ensure that his construction activities shall not cause
inconvenience to public nor there any undue interference with the normal use of
the land and water courses. Minimum necessary trees on ROU to be felled shall be
identified; permissions obtained, recorded and record shall be handed over to
COMPANY.
3.3
Taking-over, Handling, Hauling, Storing and Stringing of pipes and other

materials
3.3.1 CONTRACTOR shall receive and take-over against requisition corrosion coated line
pipe from COMPANY'S designated place(s) of issue. CONTRACTOR shall be fully
responsible for the pipe and pipe identification marking from the time of taking
delivery from the COMPANY, until such time that the pipes are installed in
permanent installation.
The CONTRACTOR shall be entitled for extra compensation for repair and
rectification of defects recorded at the time of taking delivery as per the rates set
forth in the 'Schedule of Rates'. Repair of all damages beyond such record shall be
to the CONTRACTOR'S cost. CONTRACTOR shall be fully responsible for arranging
and paying for storage areas.
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3.3.2 Materials which are susceptible of deteriorating or suffering from damages

especially due to humidity, exposure to high thermal excursions or adverse
weather conditions, shall be suitably stored and protected. Deteriorated materials
shall not be used and shall be replaced with no extra cost to COMPANY.
3.4
Pipe String
Complete pipe string shall be prepared as a single string for pulling.
3.5
Repair of Pipe Corrosion Coating

Repair of pipe corrosion coating shall be carried out by CONTRACTOR as per
relevant specification included in the Bid Package.
3.6
Lining-Up
Each length of pipe shall be thoroughly examined internally and externally to make
sure that it is free from visual defects, damage, severe corrosion, dirt, animals, or
any other foreign objects. Each length of the pipe shall be adequately swabbed,
either by use of canvas belt disc of proper diameter or by other methods approved
by the COMPANY. Damaged / corroded pipes shall be kept separate. Each length of
pipe shall be pulled through just before being welded.
3.7
Pipe Defects and Repairs

It is CONTRACTOR'S responsibility to repair all internal and/or external defects.
Immediately prior to aligning pipe for welding, the beveled ends of each joint of
pipe and the area immediately adjacent thereto (at least 25mm from the edge on
the inside and outside of the pipe) shall be thoroughly cleaned of paint, rust, mill
scale, dirt or other foreign matter by use of power driven wire buffing wheels, disc
sanders, or by other methods approved by COMPANY. This shall be done at no
extra cost.
All damaged ends of pipes that are bent, cut or otherwise mutilated such that, in
the opinion of the COMPANY, faulty alignment or unacceptable welding would
result, shall be repaired or cut-off and re-beveled to the correct angle with a
beveling machine of a type approved by COMPANY.
Dents in bevels with a depth of less than 1 mm shall be removed by CONTRACTOR
during cleaning and grinding, ahead of the welding in the field at no extra cost.
CONTRACTOR shall re-bevel dented bevel ends with a depth of dent between 1
mm and 3mm. Dents over 3mm depth shall be repaired by cutting and rebeveling.
3.8
Welding
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Welding of the Pipeline shall be in accordance with Welding Specification and

Welding Specification Charts included in the contract.
3.9
Corrosion Coating of Field weld Joints

The complete field joint shall be blast cleaned to near white metal finish to
Swedish Standard SIS 055900 Grade SA 2.5. The coating edges shall be suitably
roughed and chamfered to provide smooth transition. The joint coating material
shall be Raychems "DIRAX" or other COMPANY approved equivalent. The method
of application shall be strictly as per manufacturers recommendations and will be
subject to COMPANY approval prior to use.
Coating of field weld joints shall be carried out after pre-installation hydrostatic
testing.
3.10
Installation
3.10.1 Installation shall be carried out in accordance with approved installation

procedures.
3.10.2 The lateral offset of the actual exit point of the pilot hole from the calculated and
theoretical exit point shall not exceed two percent of the length of the crossing,
however the actual exit point shall not come outside the ROU limits of the pipeline.
The length tolerance shall not exceed one per cent of the crossing length, subject
to the condition that the actual exit point shall not be within the limits of crossing
as defined in the CONTRACT drawings.
3.10.3 Back reaming shall be done separately from the pipeline pulling operation. The
size of the back-reamed hole shall be adequate (approximately 1.5 times the
pipeline diameter) to allow enough clearance for smooth pull-back of the pipeline.
3.10.4 CONTRACTOR shall be responsible for maintaining the drilled hole till such time
the pipeline is pulled in.
3.10.5 During pulling operation, the buoyancy of the pipeline shall be controlled by
suitable approved methods so as to maintain the buoyancy as close as possible to
zero during pullback in order to reduce friction forces of the pipeline in the
hole.
Bentonite slurry of specified viscosity shall be pumped into the hole, preventing the
wall from collapsing and protecting the pipeline coating.
3.10.6 CONTRACTOR shall provide free of charge reasonable facilities to COMPANY'S
personnel to witness all stages of construction.
3.10.7 CONTRACTOR shall be responsible for the integrity of the corrosion coating and
shall apply any necessary approved protective coatings.
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Coating inspection of the pipeline after completion of pulling operation shall be

made by:
a)
Pulling the pipe to the extent possible with normal rig set up at the exit
point.
b)
Excavating the adjacent portion up to and including the first field joint.
The pipeline and joint coating shall be examined visually and with holiday
detectors for defect. The length to be inspected shall, as a minimum, be one
pipe length and one joint coating. In case damages / holidays are detected
in the first pipe length / joint, the subsequent pipe length / joint shall be
exposed and coating integrity checks shall be made. If found acceptable by
COMPANY, the first pipe length / joint shall be repaired and / or replaced as
directed by COMPANY. If the coating of second pipe length / joint is also
found damaged, CONTRACTOR shall propose further course of action and
COMPANY'S instructions shall be followed. All works shall be done at no
extra cost to COMPANY.
3.10.8 Before final hydrostatic testing, CONTRACTOR shall 'prove' the diameter of the
pipeline by passing a gauging pig through the pipeline. The gauging pig shall
have a diameter equal to 95 % of the nominal internal diameter of the pipe.
CONTRACTOR shall supply and install all temporary scraper launchers / receivers
and other equipment, piping and materials and consumable for the purpose.
3.11
Protection of Underground Utilities and Special Methods

CONTRACTOR shall obtain plans and full details of all existing and planned
underground services from the relevant Local Authorities and be responsible for
location and protection of the same.
Where the pipeline crosses other underground utilities/ structures, CONTRACTOR
shall first manually excavate to a depth and in such a manner that the utilities /
structures are located. Should any damage to any structure/utility etc. occur, the
owner / Authority concerned shall be contacted by the CONTRACTOR and repair
shall forthwith be carried out by the CONTRACTOR at his expense under the
direction and to the satisfaction of COMPANY and the concerned Owner /
Authority.
3.12
Bending
3.12.1 After pulling the pipeline across the drilled crossing, CONTRACTOR shall cut the
extended portion of the pipeline at the entry and exit points. Thereafter, the
drilled portion of the pipeline shall be cut at suitable location / depth and
extended on either bank by installing a cold field bend with minimum bend
radius of 40 times the pipe O.D. and a straight pipe length of 12 meters, such
that at the ends the top of the pipeline is minimum 1.0 meter below the
natural ground level.
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3.12.2 CONTRACTOR shall use a bending machine and mandrel (if required) and employ
approved and accepted methods of bending of coated pipe in accordance with
good
pipeline construction practice.
The procedure shall include amongst other steps- lengths, maximum degree per
pull and method and accuracy of measurement during pulling of the bend.
Cold field bends made from coated pipes shall be inspected visually and by holiday
detector to locate damages which shall be repaired by CONTRACTOR as per
COMPANY approved procedures.
The ends of each bent pipe length shall be straight and not involved anyway in the
bending. In no event shall the end of the bend be closer than 1.5 meters from the
end of a pipe or within one meter of a girth weld.
The ovality in the bent pipe shall not exceed 2.5% of the nominal diameter at any
point. A check shall be performed on all bends in the presence of COMPANY by
passing a gauge consisting of two discs with a diameter equal to 95 % of the
nominal internal diameter of the pipe connected rigidly together at a distance equal
to 300 mm.
Miter bends are not permitted.
3.13
Hydrostatic testing
3.13.1 Pre-Installation Hydrostatic Testing

CONTRACTOR shall hydrostatically test the complete pipe string of each river
crossing before installation as per approved procedure. The section of the pipeline
corresponding to the river crossing shall, before installation, be subjected to a
minimum hydrostatic test pressure equal to 1.4 times design pressure for gas
pipeline and 1.25 times design pressure for liquid pipeline. The combined
equivalent stress in the pipeline due to bending and test pressure shall not exceed
90% of the SMYS of the pipe material.
After the temperature has been stabilized, the pressure shall be maintained in the
pipeline for at least twenty four hours and recorded by manothermograph. During
the test CONTRACTOR shall check all welds for leakage. Failure, if any, during the
test shall be rectified by the CONTRACTOR. If the same is due to failure on
account of any cause other than defect in COMPANY supplied material, the repairs
shall be done free of cost, to the satisfaction of COMPANY.
3.13.2 Final Hydrostatic Test
The complete water crossing shall be tested after installation. The test procedure
shall result in a hoop stress in pipe corresponding to 90% SMYS of the pipe
material. After temperature stabilization, pressure shall be retained in the pipeline
for a minimum 4 hours and recorded by manothermograph. The hydrostatic testing
shall be carried out in accordance with approved procedures.
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3.13.3 CONTRACTOR shall prepare for COMPANY'S approval a hydrostatic test

procedure manual for pre-testing and post-installation testing of pipeline. The
test procedure manual shall include, but shall not be limited to, the following
items:
a.
For the pipe section to be tested, a diagram indicating all fittings, vents,
valves, temporary connections, relevant elevations and ratings. The diagram
shall also indicate injection locations and intake and discharge lines.
b.
Estimated amount of test water, water source, including required

concentration of corrosion inhibitors and additives, procedure for inhibitor
injection and control of concentration.
c.
Filling and flushing procedures, including a complete description of all

proposed equipment and instruments (including spares), their location and
set-up.
d.
The type and sequence of pigs and the pig tracking system for cleaning and
removal of air pockets, pig inspection procedures, including procedure to be
followed in case the gauging pig indicates damage.
e.
Procedures for leveling and stabilization after filling and for pressurization
and to allow for temperature stabilization.
f.
Pressure testing procedure including a complete description of all proposed

equipment and instruments (including spares), their location and set-up,
and proposed system for observation and recording of data during the
pressure test.
g.
Procedure for detection and location of leaks.
h.
Procedure for dewatering the pipeline section after testing, including a

complete description of all proposed equipment and instruments (including
spares), their location and set-up, the type and sequence of pigs and the
pig tracking system along with the pig specifications.
Forms for recording the testing data.
i.
3.13.4 CONTRACTOR shall furnish all necessary equipment & instrumentation for
performing the work including all temporary piping and scraper launcher/receiver
etc.
3.13.5 The test medium shall be fresh water to be arranged by the CONTRACTOR. The
water to be used shall be filtered, shall not be contaminated, and free from sand of
silt. CONTRACTOR shall submit laboratory test reports of water used for testing.
CONTRACTOR shall provide COMPANY approved corrosion inhibitors,
oxygen
scavengers and bactericides to be added to the test water. CONTRACTOR
shall
furnish and install all temporary piping which may be necessary to connect from
source of water to its pumps and manifolds / tankage.
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3.13.6 Before filling operation, CONTRACTOR shall clean the pipeline by air driven pigs
provided with spring loaded brushes and cups to remove all mill scale, rust /
sand from the internal of pipe sections.
3.13.7 The hydrostatic test shall be considered as positive if pressure has kept a constant
value throughout the test duration, except for changes due to temperature
effects, and there is no abrupt pressure drop throughout the test duration.
If test section fails to maintain the specified test pressure after isolation,
CONTRACTOR shall determine by search the location of leakage or failure. All leaks
and failures within the pipe wall or longitudinal seam shall be repaired by
replacement of entire joint or joints in which leakage or failure occurs. In those
cases where leaks occur in circumferential welds the method of repair shall be
determined by COMPANY. CONTRACTOR shall comply with instructions of the
COMPANY whether to replace a section of the line pipe that includes the line leak
or whether to repair the circumferential weld. This repair should, however, meet
the requirements of welding specification contained herein. Where failures occur in
pipeline field bends, bends shall be replaced with same degree of bends. After
completion of repairs, the hydrostatic test shall be repeated in full, as per the
approved procedures.
All work of reinstating line pipe, to replace failures, shall be done in accordance
with the specifications contained herein.
CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage
locations designated by the COMPANY. All cracks and splits resulting from failures
shall be coated with an application of grease to preserve the characteristics of
failures from corrosion. Joints of failed pipes shall be marked with paint, with a tag
indicating failure details, date and location of failure and pressure at which failure
occurred.
3.13.8 After completion of successful hydro test of the above portion, the pipeline shall
be capped and buried. Pipeline end position on the banks shall be marked on the
ground by installing location markers on both banks approved by COMPANY.
3.14
Permanent Pipeline Markers

On both banks of each river crossing, CONTRACTOR shall install a Navigable
Waterway Pipeline Crossing Warning Sign, if in accordance with Std. No. S-04-01019. CONTRACTOR shall supply all materials and fabricate and install the markers
as per reference drawing. Wherever feasible, the pipeline markers shall be installed
on the embankments, however, exact location shall be decided based on site
conditions and as directed by COMPANY.
3.15
Fencing
CONTRACTOR shall supply all materials and install G.I. Wire Chain link security
fencing of size 10mx10mx2.5m high with lockable steel gate around the pipe ends
and test stations for temporary C.P. on both sides of each river crossing.
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3.16
Idle Time Preservation of Pipeline

If directed by COMPANY, CONTRACTOR shall supply all materials and consumable
including water and inhibitor and shall install all piping connections, valves,
instrumentation, etc., and perform all works for preservation of pipeline by
pressurization with inhibited water. CONTRACTOR shall use approved inhibitors
and shall determine the required dosages of inhibitors and pressure for idle time
preservation of the pipeline for a period of maximum six months from the date of
completion of construction. Corrosion inhibitors and dosages shall be subject to
COMPANY'S approval prior to use.
3.17 Final clean up

After completion of construction, CONTRACTOR shall clear the sites of all balance
material and debris. All balance pipe lengths supplied by COMPANY shall be
returned to COMPANY'S designated stock yard(s). Site shall be cleared to the
complete satisfaction of COMPANY and authorities having jurisdiction. All such
works shall be done at no extra cost to COMPANY.
4.0
DOCUMENTATION
4.1
In addition to the documents specified elsewhere in this specification,

CONTRACTOR shall submit to the COMPANY six copies of each of the following
documents/ records:
4.2
Complete record of pipes 'taken-over' from COMPANY, number of pipe

lengths used, and record of return of balance pipe lengths to COMPANY'S
designated stock-yard(s)
During the course of execution of the crossing, CONTRACTOR shall generate /

compile the following data. It shall be obligatory on part of the CONTRACTOR to
furnish this data to COMPANY in the event it is required for.
Detailed drilling log and down hole data, including, but not limited to, the
following:
a)
Torque and pulling / pushing force
b)
Data on drilling fluid.

i.
Density
ii.
Type of mud and additive employed.
iii.
Mixing, pumping and cleaning.
Wash and drill pipe data, viz.,
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a)
Dimension and material properties.
b)
Data on API classification.
C) Age of and type of inspection previously carried out on these pipes.
4.3
4.4
Copies of the permits obtained from authorities having jurisdiction for the
various works.
Plan & profile of the drilled hole along with the water level variations.
Records of hydrostatic pre-testing and final testing.
Record of Non Destructive Testing of welds.
Clearance certificates form the landowners and Authorities having

jurisdiction regarding satisfactory clean-up and restoration of pipeline ROU
and work areas.
After completion of construction, CONTRACTOR shall prepare and furnish six sets
of copies and two sets of reproducible of As-Built drawings for the crossings. As
built drawings shall, as a minimum include the following information:
True profile of the river bed and banks along the pipeline;
True profile of the pipeline as installed and the depth of cover to top of pipe
at regular intervals
Location of entry and exit points and angles of entry and exit, along with
lateral offset of exit point from the original pipeline alignment
Location and angle of field bends
Location of pipeline markers.
All documents shall be in English language.
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DOCUMENT NO.
S-04-02-025
REV-0
Page 15 of 15
FOR
CONSTRUCTION OF PIPELINES
CROSSING ROADS, RAIL ROADS AND
MINOR WATER CROSSINGS
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CNSTRUCTION OF PIPELINES CROSSING
ROADS, RAIL ROADS AND MINOR WATER
CROSSINGS
SPECIFICATION
S 04 02 026
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Page 1 of 11
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1.0
SCOPE
This specification covers the minimum requirements for the various activities to be
carried out by the Contractor for or about the installation of pipelines crossing roads,
railroads, minor watercourses and other services.
The provisions of this specification are not applicable for pipelines crossing water
courses, which are specifically designated as "Major Water Courses" in the CONTRACT.
1.2
and documents included in the CONTRACT between Company and Contractor. Unless
specified otherwise, all sections of this specification shall apply to all specifications
2.0
REFERENCE CODES, STANDARDS AND SPECIFICATIONS
2.1
the time of floating the enquiry) of the following codes, standards and specifications.
a)
ASME B 31.4 -
Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids
b)
ASMEB 31.8
Gas Transmission and Distribution Piping systems.
c)
API RP 1102 -
Recommended practice for Liquid Petroleum Pipelines

Crossing Railroads and Highways.
d)
OISDB141 -
Design and Construction requirements for cross-country

hydrocarbon pipelines
e)
2.2
Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line
(US DOT - Pipe Line Safety Standards).
f)
Part195
Transportation of liquids by Pipe Line

g)
GAIL Standard Specifications:
i)
Standard Specification for Pipeline Construction (Onshore)
ii)
Welding Specification for Onshore Pipelines for Transportation of Gas
In case of conflict between the requirements of above mentioned codes, standards,

specifications and practices, the most stringent requirement shall govern. In case of
conflict between the requirements of this specification and that of the above referred
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codes, standards, specifications and practices, the requirements of this specification

shall govern.
2.3
For the purpose of this specification the following definitions shall hold:
-
the words 'Shall' and 'Must' are mandatory.

recommended.
3.0
GENERAL
3.1
Crossing of roads, railroads, buried services. canals and minor water courses with
equipment and/or personnel is allowed only after acquiring approval from the
authorities having jurisdiction and after making arrangements for safeguarding the
roads, etc. and the verges and/or banks thereof and the buried services with
appropriate provisions.
Highways, Main-Roads and Railroads and their verges and banks of water crossings are
not allowed to be used for loading, unloading or stacking of materials and/or
equipment. For secondary roads, such loading/unloading is permitted only after prior
approval from the concerned authorities. Contractor is not allowed to close or divert
roads or watercourses without prior approval from the Company and the concerned
authorities. Contractor shall never unnecessarily hamper the users of the roads,
railroads, buried services and/or watercourses. The water flow shall not be obstructed
in any way.
All Civil and Mechanical works associated with or incidental to the installation of pipeline
crossings shall be carried out in accordance with GAIL Specification "Standard
Specification for Pipeline Construction (Onshore)".
3.2
Company reserves the right to demand for individual crossings from the Contractor a
separate detailed report for approval, containing:
-
Approval letter from concerned authorities
Time Schedule
Execution methodology with details of equipment
Test procedure
Manpower deployment
Calculations/Description of temporary works
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Design calculations for crossing
Soil investigations, etc.
Such works shall be without any extra cost to Company.

3.3
Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically pretested ex-situ, prior to joint coating, whenever,
-
Crossing is executed by boring of carrier pipe:
Crossing is installed in casing pipe;
River Crossing pipes which are to be continuously concrete weight coated
Whenever, in Company's opinion, the repair of pipeline at crossing, in case of a

leak during final hydrostatic testing, would require inordinate amount of efforts
and/or time;
Whenever pretesting is insisted upon by the Authorities having jurisdiction over

the utility crossed.
The section of the pipeline for the crossing shall be tested as a single string. Unless
specified otherwise in the CONTRACT, the test pressure shall be the one resulting in
hoop stress corresponding to 90% of SMYS of pipe material. Test pressure shall be
retained in the pipeline for minimum period of four (4) hours. Test section shall be kept
under surveillance by regular patrols during test and it shall be visually examined for
leaks/defects, etc.
4.0
ROAD AND RAILROAD CROSSINGS
4.1
The work under crossings shall include necessary clearing, grading and trenching to
required depths and widths, welding of casing (when required) and carrier pipes,
lowering-in, back filling, clean-up, restoration to the original condition and further
strengthening and protective works, testing, installation of assemblies, insulators and
end-seals, and temporary works such as sheet piling, bridges, etc.
The work shall be carried out in accordance with the approved drawings and job
standards, as directed by Company and to the satisfaction of Company and the
authorities having jurisdiction over the facility crossed. The work carried out for road
and railroad crossings shall meet the minimum requirements of API RP 1 102.
Before the installation work of crossings is started, the Contractor shall provide suitable
barricades, temporary bridge / bypass work (especially where roads are open-cut) with
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railing, if required by Company for safety of traffic. Adequate traffic warning signals
and/or traffic lights and suitable diversions shall be provided as directed by
Company/Authority having jurisdiction over these areas. Such diversions shall not cross
the pipeline where it has already been installed, unless proper safeguarding at
Company's opinion is ensured.
Prior approval from the statutory authorities shall be obtained to lay the pipeline across
the highway/road either by boring or by open -cut method. Installation of the crossing
shall be by the method (i.e., boring/open-cut) approved by Authorities having
jurisdiction. Railroad crossings shall always be bored/ jacked.
4.2
Boring/ jacking of carrier pipes for crossings is allowed only if the pipes for boring/
jacking are provided with a suitable corrosion coating and Contractor remains liable for
the suitability of the pipe and weld-coating of carrier pipes to be bored and type of
coating and method of application are anyhow to be authorized by Company without
prejudice to Contractor's liability. In all other cases the carrier pipes shall be cased.
Before start of the boring/ jacking operation, Contractor shall execute soil investigations
and determine the ground water table. Based on these investigations, Contractor shall
prepare a construction drawing and submit to Company for approval including time
schedule and soil investigation report.
During the execution of the boring, the ground water table over the length of the
boring shall be lowered up to at least 0.50 m below bottom of the pipeline. This water
table is to be regularly inspected and maintained by Contractor and reported to
Company. To safeguard the stability of the bore pit, contractor shall, if necessary in
Company's opinion, use a closed sheet piling, which shall extend at least over 50% of
the length in undisturbed soil. The length of the boring shall be in accordance with the
width of the ROU of the crossing (road, railroad, etc.), with minimum 0.6 m extra on
either side.
If the soil conditions and ground water for a particular boring give reasons for this,
Contractor is entitled to suggest to Company for a relaxation of one or more of the
following requirements as defined here forth.
Soil investigation
Lowering of ground water table
Sheet piling
Length of boring, etc.
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In approaches to the crossing, Contractor shall eliminate unnecessary bending of pipe by

conforming to the contour of the ground by gradually deepening the ditch at such approaches
as directed by the company.
4.3
The bottom of the trench and/or the pit for at least twelve (12) meters at the approach
to each end of a casing shall be graded and if necessary backfilled with clean sand and
compacted up to atleast 95% Proctor Density to an elevation that will provide sufficient
and continuous support to the pipeline so that the pipeline remains correctly aligned at
casing ends during and after backfilling.
4.4
The diameter of the hole for a bored section shall have a hole diameter as close as
practicable to the outside diameter of the carrier or casing pipe. If excessive void or too
large hole results, or if it is necessary, in the opinion of Company, to abandon the bored
hole, prompt remedial measures such as filling the hole with suitabie material shall be
taken to the entire satisfaction of the company and Authorities having jurisdiction
thereof at no extra cost to Company. Equipment used for installation of casing pipe
shall be of the type approved by Company.
An installation consisting of hydraulic jacks shall be provided with easily readable
pressure gauges (in bar) and sealable pressure limits. Their proper operation shall be
demonstrated before the work is started. Company can request that the maximum
pressing force be limited.
At the front of the pipe there may be a cutting ring, which may be 12 mm large than
the outside diameter of the pipe or casing. A lubricating pipe can also be used in
jacking, the nipples of which shall not protrude from the cutting ring. Said lubricating
pipe shall not be fixed to the pipe or casing. When jacking, only biologically degradable
lubricants shall be used (e.g. WRC Medlube or an emulsion of bentonite).
Removal of soil from the pipeline during jacking shall be done mechanically by means of
a standard, locked auger, which has to be safeguarded against jacking ahead of the
pipe. If, in the opinion of the Company, fluid sand may arise, an inner pipe with funnel
shall be used.
During jacking, the progress of the pipe to be jacked and the cutting capacity of the
auger shall be mutually adjusted, by regulating the speed of auger, to prevent the road
from bulging (rpm too low) or cave-ins (rpm too high). In any case no more soil shall
be removed than the volume of the pipe. The auger drive shall be provided with a
clutch.
The progress in the work, the readings of the gauge pipes, the jacking pressures
observed, etc., shall be recorded in a log book, to be shown to Company upon request.
All information shall be supplied to Company on completion of the work.
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CROSSINGS
SPECIFICATION
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If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and
plugged at either end. The diameter of the casing pipe shall be as indicated in the job
standards.
Company reserves the right to inspect certain lengths of pipes to assess damages, if
any, to the corrosion coating of the carrier pipe used for boring. Contractor shall weld
additional lengths of pipe and pull the required extra lengths for Company's inspection.
If during inspection any defects are noticed, Contractor, in consultation with Company,
shall carry out the remedial measures, as required.
4.5
While welding of the casing and vent/ drain pipes, internal high or low is not allowed.
Welding of casing and vent/drain pipes need not be radiographed, however, only
normal visual checks shall be carried out. Before welding, the single length of pipe shall
be inspected in order to check that there is no out of roundness and dents. When such
defects are noticed, these must be completely removed before joining the pipes. If
these defects cannot be repaired, the defective section shall be cut out.
4.6
In the case of crossings where excavation has been authorised, the welding for the
casing pipe and for a continuous section of the pipeline corresponding to the expected
length shall be carried out in the proximity of the crossing. Casing must be laid
immediately after the trenching. Casing pipe must be laid with a single gradient in order
to allow for an easy insertion and, if necessary at a future date, to allow for the removal
or replacement of the pipeline, leaving the casing undisturbed. The direction of gradient
shall be marked in the crossing drawings for future reference.
4.7
The installation of assembly of vent pipe units as approved by Company shall be carried
out by direct insertion and welding to the ends of the casing pipe before introducing the
carrier pipe to avoid damage to insulators from welding heat. The operation of
assembling and extending the vent pipe shall be carried out in such a way that there is
no contact with the carrier pipe. The painting/ coating of the vent pipes shall be applied
before backfilling as per relevant specifications.
4.8
The casing pipe shall be considered ready for installation of the carrier pipe, after
careful inspection and internal cleaning with the removal of soil, mud, stones and other
foreign materials.
4.9
Insulators, as approved by Company, shal1 be securely fastened to the pipe with all
bolts and fixtures firmly tightened. The number of insulators and spacing shall be as
shown in the drawings or at 2.5 meters center (whichever is more stringent). At the
end of both sides of the casing, a double set of insulators shall be installed.
4.10
Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is
aligned correctly in the casing and that the pushing or pulling force is evenly and
constantly applied to avoid damages to the insulators. A nose piece having a diameter
equal to that of the pipe shall be welded on the front and back end of the carrier pipe
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to facilitate installation of the carrier pipe properly in the casing and to keep it dry and
clean.
4.11
After installation of the carrier pipe section, the casing and the appurtenances, but prior
to making tie-in welds and backfilling, an electrical test shall be conducted by the
Contractor in the presence of the Company, to determine the resistance between the
casing and the carrier pipe or the carrier pipe and the soil. These tests shall show at
least a resistance of 100,000 ohm M2 . After backfilling and compaction, additional
tests shall be conducted to determine if the casing is electrically shorted to the pipe. If
the installation is found to be shorted, Contractor shall make the necessary corrections
and repairs at his cost, unless a test to the satisfaction of the Company is obtained.
4.12
After successful installation of crossing to the satisfaction of Company/ Authorities

having jurisdiction, the nose pieces/ pulling head welded to carrier pipe as an
installation aid shall be cut/ removed and ends of carrier pipe shall be beveled/
prepared for further welding/ tie-in with the balance section of pipeline on either side of
crossing. Casing end-seals shall be installed/ fitted prior to back filling.
5.0
CROSSINGS OF BURIED SERVICES
5.1
The pipeline under construction may pass above or below the existing buried facilities
such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of
cover as required in the drawings and specifications are guaranteed. The clearance
required between pipeline and the existing facility shall be 500 mm (min.) as indicated
in job standard.
5.2
Whenever buried services in the ROU are to be crossed by Contractor, Contractor shall
safeguard the buried facilities and the required protecting precautions shall be executed
as approved by Owners of the buried services and by Company.
For buried services to be crossed by boring/ jacking, the relevant provisions of Section
4.0 shall apply.
5.3
6.0
MINOR WATER COURSE CROSSINGS
6.1
Minor water crossings are crossings of (future) ditches, canals, water courses, rivers,
streams etc., whether the bed(s) contain(s) water or not, and such crossings are not
being specified as "Major Water Crossings" in the CONTRACT.
6.2
For minor water crossings a standard drawing or a separate detailed approved drawing
for individual crossing shall be applicable, and all further specifications are applicable.
6.3
Wherever minor water crossings in the ROU are to be crossed, Contractor shall install
bridges and further comply with the provisions as laid down in this specification.
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6.4
In crossings of water courses with either moderate flow rate or of torrential nature with
marked and unpredictable flooding, an adequate survey shall be carried out before
starting the work with the object of determining what precautions are necessary and
the most favorable period for executing the work.
6.5
In case of crossings of water courses for which no special methods of laying are
required, a pipe section of a size as per the approved drawings shall be assembled and
subsequently laid. Bends shall be of cold field type.
Whenever required by Company, Contractor shall, before start of construction, execute
soil investigations. Based on the soil investigations, the Contractor shall prepare a
construction drawing, work method and time schedule for approval by Company.
The depth of the existing bottom of a minor water course crossing shall be determined
in relation to the adjacent ground level by taking the average of four measurements.
Measurements shall be taken with a gauge rod and with dimensions 60x60 mm and
having a flat bottom. The minimum force to be exerted shall be 360N (36 kgf).
Contractor shall take special care to check with the responsible authorities for special
conditions applying to working on, over, under or thorough minor water crossings and
Contractor shall comply with any such conditions. Written arrangements with authorities
shall be drawn up in cooperation with Company.
6.6
The minimum cover over the pipe shall be as specified in the relevant approved
drawings and job standard.
6.7
For crossing beneath the bed of water courses, the pipe section shall be made in such a
way that it conforms to the existing or future bed as indicated in the approved
drawings. In crossings for which an individual drawing has not been prepared, the
minimum cover of the pipeline shall not be less than that indicated in the standard
drawings for a similar type of crossing.
6.8
Whenever the crossing requires a straight section of pipe between the lower bends
coinciding with the river bed, this section shall be laid at a single horizontal level.
6.9
For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall
be prepared, laid and tested in accordance with the applicable clauses of Section 4.0 of
this specification.
6.10
The Contractor shall arrange temporary installation of diversions as may be necessary,

to ensure the effective functioning of these watercourses crossed, to the entire
satisfaction of the concerned local Authorities as well as the Company.
6.11
Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by Company and shall be thoroughly compacted to prevent soil and bank
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erosion as per the drawings and standards to the satisfaction of authorities having
jurisdiction thereof and the Company. Whenever boulders, rock, gravel and other hard
objects are encountered, they shall not be placed directly on the pipe. Sufficient earth,
sand or selected and approved backfill material shall be backfilled initially around and
over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 300 mm around the pipe before backfilling remainder of the trench with
excavated or other material as per approved drawings and standards.
After the trench has been backfilled and during the clean up works, the minor water
crossing shall be cleaned across the whole width of the ROU.
When specified in the CONTRACT, Contractor shall repair the ditch bank with materials
to be supplied by him as follows:
6.12
The excavation shall be backfilled with well compacted solid soil, followed by a
minimum 0.25 m thick layer of properly shaped boulders (75- 150 mm) encased
in a net of galvanized iron wire of dia 3 mm spaced at a maximum distance of 50
min to be laid over the backfilled, compacted and graded banks.
The lengths of the above protection shall be equal to the bank excavation and
damage and extending 2 m on either side. The width of this protection on the
slope shall be determined by the following:
-
2 m plus the highest water level
Up to the bottom of the crossing or 20 m below the highest water level

Which ever is smaller.
The crossing of any embankments shall be carried out strictly in accordance with
approved drawings.
No drilling work on embankments shall be permitted without prior written approval from
the competent Authorities.
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FOR
MAJOR WATER CROSSINGS
(CONVENTIONAL TRENCHING)
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STANDARD SPECIFICATION FOR MAJOR

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Abbreviations:
ASME
American Society of Mechanical Engineers
API
OISD
Oil Industry Safety Directorate
ROU
Right of Use
US DOT
Unite States Department of Transportation
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1.0
SCOPE
1.1
This specification covers the minimum requirements for the various activities to be
performed by contractor for the construction of pipeline major water crossings by
conventional trenching method. Provisions of this specification are applicable only for
"Major Water Crossing" specifically named as such in the CONTRACT.
1.2
and documents included in the CONTRACT between Company and Contractor.
1.3
Contractor shall, with due care and diligence, execute the work in compliance with all
laws, by-laws, ordinances, regulation etc., and provide all services and labor, 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 a
temporary of permanent nature.
1.4
Contractor shall take full responsibility for the suitability, stability and safety of all
operations and methods involved in the work.
1.5
Contractor shall be deemed to have inspected and examined the work area and its
surroundings and to have satisfied himself so far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic conditions,
the extent and nature of the work and materials necessary for the completion of the
work, and the means of access to the work area.
1.6
Contractor shall be deemed to have obtained all necessary information subject as above
mentioned as to risks, contingencies and all other circumstances, which may influence
the work.
1.7
Contractor shall, in connection with the work, provide and maintain at his own costs all
lights, guards, fencing, watching etc., when and where necessary or required by
Company or by any duly constituted Authority for the protection of the work and
properties or for the safety and the convenience of public and/or others.
2.0
REFERENCE DOCUMENTS
2.1
the time of issue of enquiry) of the following codes, standards and specifications:
a)
ASME B 31.4
Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids
b)
ASMEB31.8
Gas Transmission and Distribution piping systems.
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c)
API RP 1102
Recommended practice for Liquid Petroleum Pipelines

Crossing Railroads and Highways.
d)
OISDB 141
Design and construction requirements for crosscountry hydrocarbon pipelines
e)
Part 192, Title 49
Transportation of Natural and other Gases by Pipe

Line
f)
Part195

g)

i)
ii)
Welding Specification for Onshore Pipelines for Transportation of Gas
2.2
In case of conflict between the requirements of above mentioned codes, standards,

specifications and practices, the most stringent requirement shall govern. In case of
conflict between the requirements of this specification and that of the above referred
codes, standards, specifications and practices, the requirements of this specification
shall govern.
2.3
-

recommended.
3.0
GENERAL
3.1
All works of the pipeline major water crossing shall be performed in accordance with
the approved construction drawings, procedure, and other applicable documents as per
the CONTRACT, good pipeline practices and as directed by Company.
3.2
Before start of the field construction, Contractor shall submit in triplicate to Company,
for approval, for each major water crossing, a complete report containing at least:
i)
Installation method.
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ii)
Proposed time schedule indicating start and finish dates and detailed break-up of
time period for all critical activities associated with the work.
iii)
Required work area along with layout and location.
iv)
Equipment to be used (including number and capacity of equipment).
v)
Manpower deployment during construction.
vi)
Proposed sub-contractors and/ or vendors along with their scope of work.
The description of the installation method as a minimum shall include the following:
a)
Study of water currents in relation to the method of launching (on bottom and
on surface).
b)
Calculations for stability of pipeline during launching and final test.
c)
Buoyancy Studies.
d)
Preparation of fabrication yard and launching areas along with proposed layouts.
e)
Pipeline construction details (including hauling, stringing, welding, NDT, concrete

coating, etc.).
f)
Pre-test procedure.
g)
Procedure for corrosion coating of field joint.
h)
Dredging, anchoring requirements, spoil deposit and trench survey method and
Contractor's proposed methodology for execution of these activities.
i)
Pulling or other installation method and related calculations/analysis including

rope test, checking of winch/crane pulling capacity etc.
j)
Pulling arrangement including launch way and anchoring and braking device.
k)
Trench correction before launching.
l)
Method of positioning and sinking/ lowering of pipeline.
m)
Method of rectification of damages to the pipeline/ coating, during launching.
n)
Method of backfilling, bank protection and survey.
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o)
Final test procedure after backfilling.
p)
Safety system adopted during rope/ winch capacity test and during construction
including launching.
q)
Communication system adopted during construction/testing/survey.
r)
Abandonment and recovery procedures.
Company shall inform Contractor within 21 calendar days, if any objection against the
document and procedures described requires resubmission by Contractor.
Approval by Company of the methods used by Contractor shall in no way relieve
Contractor from the sole responsibility for safe and satisfactory installation of the
crossing.
3.3
Contractor shall comply with all the conditions and requirements issued by Authorities
having jurisdiction in the area where the work is to be performed. Contractor shall, at
his own responsibility, obtain necessary permits from the Authorities having jurisdiction,
for performing its work.
If no public roads exist, Contractor shall arrange at his own for access to work areas at
no extra time and cost to Company.
3.4
Pre-construction surveys
Prior to start of any work, Contractor shall carry out a survey of the major water
crossings and acquaint himself with site conditions and to collect any data regarding the
water velocity and the tidal variation in the flow pattern and shall verify the suitability of
his equipment and the method of Construction.
4.0
TRENCHING
4.1
Dredging / Excavation
4.1.1 Contractor shall dredge or excavate the trench for the water crossing in conformity with
the approved drawings. Dredging of the trench shall be executed as accurately as
possible.
4.1.2 The trench shall be excavated to such depth as required to provide the minimum cover
and the pipeline configuration as specified. The pipeline profile of the crossing shall be
followed as accurately as possible. Before laying, the trench shall be cleaned and
leveled. The trench shall be subject to inspection by Company prior to installation of the
pipe.
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4.1.3 Navigational traffic shall not be obstructed, unless permission has been given thereto.
Contractor shall issue all necessary publication according to the local requisitions.
Instructions given by Authorities shall be followed accurately and immediately, so that
traffic encounters no hindrance.
Contractor can not request a compensation if his work is hampered or delayed due to
weather conditions, any obstacles/or any traffic on the spot, where work is executed.
4.1.4 Contractor is fully responsible for the execution of the blasting (wherever permitted),
the dredging and excavation work, hopping of the spoil, transportation, dumping on
land or in water, all to be executed in agreement with Authorities, land owners and
Company.
4.1.5 Contractor may be obliged to dredge or excavate a trench deeper or wider than
indicated in the drawings in order to properly lay the pipeline in unstable (underwater)
areas, or near and adjacent to the banks of water-courses. It shall be understood that
Contractor is aware of such problems at the time of his Bid and that, when such
additional excavation is required, it shall be done by Contractor as part of the work and
that he will install the necessary provisions and/ or temporary works such as sheetpiling, special filling materials, etc. at no extra cost to Company.
4.1.6 During the execution of dredging work by Contractor, bearings, measurements and
levels shall be taken by or on behalf of Company. Contractor shall render assistance for
this purpose and make available for Company appropriate survey boats, fully manned
and equipped, before the trench excavation work of the water crossing can be started
Contractor, if so desired by Company, shall make cross profiles at intervals of not more
than 10.0 m of the bottom of the watercourse along the surveyed centerline of the
water crossing. In such a case, horizontal measurements shall be taken by triangulation
or tapping between known points and shall be made with such accuracy that the
location of each vertical measurements is known with 1.0 m. Vertical measurements
shall be taken with a sonic recording device, or with line and rod, as directed by
Company and shall be taken with such an accuracy that each depth is known within 0.2
m. Vertical measurements shall be taken at points averaging not more than 5.0 m apart
and no two measurements shall be more than 7.0 m apart. The cross profiles shall
extend at least 10 in on both sides of the top of the trench.
All measurements shall be recorded by Contractor. Company may witness such
measurements. The resulting profile, corrected to the elevation of the undisturbed
watercourse, shall then be the reference profile. Said profile shall be plotted on a 1:200
vertical and horizontal scale.
4.1.7 Contractor shall keep the trench in good condition until the pipe is laid, and no claim is
to be made to the Company by reason of its caving either before or after the pipe is
laid. Contractor shall do whatever is required to excavate the trench, install the pipe in
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it and backfill the trench in accordance with the specifications at no extra cost to
Company.
4.1.8 Immediately before installation of the water crossing in the excavated trench,
Contractor shall prepare a profile of the trench bottom along the surveyed center line of
the water crossing for comparison with the reference profile. Contractor shall also make
cross sections of the trench at intervals of not more than 50 m. All profiles and cross
section measurements shall be taken as specified and, if required, shall be witnessed by
Company. These data shall be submitted to Company for approval and Company will
approve or reject the trench excavation as completed within 24 hours after receipt of
the profile and cross sections.
4.1.9 Contractor shall grade the trench in such a manner as to give the maximum amount of
uniform support to the pipeline when it is lowered or pulled into place. The maximum
unsupported span shall not exceed 10.0 m.
4.1.10 In submerged sections, where rock or gravel is encountered in the bottom of the
trench, padding is required. The thickness of the padding under the concrete coated
pipe shall at least be 0.5 m and after installation at least 0.5 m around the pipe.
Blasting, if any, and padding shall be included in the contractor's work.
4.2
Pumping Line
In case Contractor uses pumping lines to discharge the spoil, he shall take care of the
necessary permits.
Pumping lines, discharges and siphons shall be installed by Contractor and removed
before the completion of the work. At crossing with existing roads, the pumping lines
shall be led through a casing pipe boredljacket under the road or led through a porch
over the road. A stress calculation must then be handed over to Company. The
necessary provision to embank the dumping area and also the spoil-basins shall be
made by Contractor. Contractor is responsible for transportation of the spoil and
dumping on land and is liable for damage to works of third parties caused by leakage of
pumping lines, etc. Contractor shall at all time prevent overflow of pumping water, spoil
or sand over embankments, parcels or roads. Further more, Contractor shall safeguard
Company from claims of compensation by third parties due to encountered damage.
4.3
Spoil
Spoil which is not dumped on and including spoil acquired after cleaning the water
crossing trench, shall be transported and dumped in places, designated thereto by
agreement between Contractor and authorities and approved by Company. Spoil shall
be transported in (split), barges; only those barges shall be used that avoid spilling
during transportation due to incorrect closing of the flaps, etc. Spoil, which is dumped
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outside the designated places shall be removed by Contractor at first notice by

company.
4.4
Dikes, Dams and weirs

Contractor shall install temporary provision in the existing dikes, dams, etc. to prevent
flooding of low areas. Therefore in general, in existing dikes, dams, etc. a double
substituting weir must be installed before start of excavation in the existing dike or
dam. Such a double substituting weir can be a closed wall of sheet piling, supported by
soil. The provisions shall be such that the underwater profile of the dredged trench, the
water movement caused by ships etc. cause no slide/ cave-ins of the dike or dam.
4.5
Pollution Control Measures

Contractor shall take all necessary precautions not to pollute river water and banks
during entire construction operation. Equipment deployed and construction
methodology adopted shall be such that minimum damage is caused to the existing
environmental conditions. Union and State Government requirements concerning
pollution control and environmental protection shall be fully complied with.
5.0
CONTINUOUS CONCRETE COATING

Contractor shall provide concrete coating over the pipeline including the bends in
accordance with the specification issued for the purpose and approved procedure.
Contractor shall coat the weld joints in order to arrive at the continuously concrete
coated pipeline. However the concrete coating shall be applied after the hydrostatic
pretest.
6.0
HYDROSTATIC PRE-TESTING
Contractor shall hydrostatically pre-test the pipe string of each water crossing before
installation as per approved procedure.
Joint coating of the welds shall be done after this pre-test.
The section of the pipeline corresponding to the major water crossing shall, before
installation, be subjected to hydrostatic pretesting on a combined equivalent stress of
90% of the SMYS of the pipe material. After the temperature has been stabilised, the
pressure shall be maintained in the pipeline for at least twenty-four hours and recorded
by manothermograph. During test, the Contractor shall check all welds for leakage.
Failure, if any, during the test shall be rectified -by the Contractor. If the same is due to
failure on account of any cause other than defect in materials supplied by Company, the
repairs shall be done free of cost, to the satisfaction of Company.
7.0
INSTALLATION
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7.1
Contractor shall submit a detailed scheme for the method he proposes to adopt for
installing the pipeline to Company for approval. Contractor shall calculate all stresses in
the pipeline while laying and check whether the stresses remain within permissible
limits. A set of all calculations shall be submitted to Company for approval.
7.2
Contractor shall perform all work required to install the water crossings, including the
possible appurtenances indicated in the drawings. The water crossings shall be installed
in such a manner as to comply with the requirements and conditions stated by the
Authorities issuing the permits. Contractor shall pay special attention to minimise any
damage to embankments and dikes in the vicinity of water crossings.
7.3
The equipment for launching shall be arranged in such a way that the pipeline is laid
without impact or jerking and is not subjected to stresses of any type other than those
which are allowable. Minimum allowed radius of curvature shall be followed, particularly
at the end of the launching way towards the water in the freely suspended section.
During the launching the Pipe shall have a submerged weight of 30 kg/ meter with a
tolerance of & l0%.
7.4
After the water-crossing section has been installed in place, Contractor shall fill this
pipeline section including the pertaining land pipeline sections with water for the final
testing.
7.5
Contractor shall check if the position and depth of the water crossing are in accordance
with the approved drawing, by means of a profile of the pipeline, before and after the
water-crossing section is filled with water. Contractor shall lower each pipeline section,
which is not sufficiently deep by dredging or jetting the underlying ground.
7.6
The maxiinuin allowed horizontal deviation from the required center-line shall be limited
by the following:
-
For pipeline dia up to including 500 mm :
300 mm
For pipeline dia greater than 500 mm
500 mm
7.7
Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom
contour of the trench grade, so that it will be firmly, uniformly and continuously
supported within the permissible limits of unsupported spans as specified in Para 4.1.9.
Company may employ a diver or use other suitable methods to inspect the bottom of
the trench and/or after the pipe is installed prior to backfilling of the trench. Contractor
shall facilitate the work of the diver and shall furnish the necessary equipment and
helpers necessary for the diver/ inspector to perform his work.
7.8
If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy
the minimum requirements of cover as specified in approved drawings, the Contractor
shall make necessary corrections to either trench or to the pipe alignment or to both so
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that the pipe, when finally in position in the trench, shall fully meet the specification,
failing which Contractor may be asked to remove the pipeline. This shall be done at no
extra time and cost to the Company.
7.9
Installation of Parallel Pipelines

When parallel pipelines are required to, be installed across major water crossing,
Contractor shall further comply with the following requirements.
7.9.1 Depending on the diameter of the parallel pipelines, the characteristics of the crossing
and the limitation of Contractor's equipment, Contractor may propose installation of the
parallel pipelines either together in a combined operation or separately in a common
trench.
7.9.2 If the pipelines are installed together, the minimum clear distance between the parallel
pipelines (measured from the outside diameters of the concrete coated pipes) shall be
300 mm. Contractor shall provide spacers (at sufficient intervals along the length of the
pipe sections), securely fixed to the pipes, or shall propose other suitable alternative
methods, so as to ensure that the stipulated minimum clear distance is maintained. The
buoyancy of the combined installation (pipes+spacers) shall be checked before
installation. The spacers may be removed before the trench is backfilled.
Contractor shall furnish detailed drawings/calculations for the pipe assembly, showing
the details of spacers/ other arrangements for Company's approval before start of
construction.
7.9.3 If the parallel pipelines are installed separately in a common trench, the minimum clear
distance between the parallel pipelines in the trench shall be 5000 mm. Contractor shall
ensure that this minimum spacing is maintained till the time the trench is backfilled.
7.10 Construction Equipment
All critical construction equipment deployed shall have a factor of safety of 2 (minimum)
over the calculated loads/capacities.
8.0
BACKFILLING AND BANK PROTECTION
8.1
Backfilling of the water-crossing section shall be performed as described in the following

clauses.
8.1.1 The bottom of the water way shall be reinstated to its original level by backfilling the
trench in a manner and with suitable material and as prescribed and approved by the
Authorities and Company. In case material other than the original spoil is required, this
shall be supplied and applied by Contractor.
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Wherever boulders, rock, gravel and other hard objects are encountered, they shall not
be placed directly on the pipe.
Sufficient earth, sand or selected and approved back fill material shall be backfilled
initially around and over the pipe to provide a protective padding or cushion extending
to a minimum thickness of 0.5 m around the pipe before backfilling remainder of the
trench with excavated or other material.
Wherever required by Company, Contractor shall cover the nearly backfilled trench with
a layer of rock boulders to be approved by Company over a width equal to the width of
excavated trench with an extra of 5m on either side at no extra cost to Company.
8.1.2 Backfilling progress of the trench shall be checked continuously and a daily progress
report shall be made in three-fold and handed over to Company.
8.1.3 All embankments and/or dikes, bed and banks shall be reinstated to their original state
and levels, unless otherwise prescribed in the drawings or by the competent Authorities
or Company.
8.1.4 All remaining spoil-deposits shall be cleaned by Contractor to the satisfaction of
Company.
8.2
Bank Protection
Trenches in banks of major water crossing shall be backfilled with soil approved by
Company. The fill at the banks shall be compacted firmly and reinforced with sacked
earth, rip-rap, or by other means as directed by Company to the satisfaction of
Authorities having jurisdiction thereof. In areas where the backfilled soil is expected to
be of loose type, which is prone to flow, the trench shall be backfilled with crushed rock
of size approved by Company and pipe shall be provided with adequate padding of soil
of a quantity approved by Company. After the trench has been backfilled and during the
clean up works, the water crossing shall be cleaned across the whole width of ROU.
Unless stipulated otherwise by the Authority or by Company, Contractor shall protect
the banks of the major water crossings by using gravel and boulders filled embankment
mattresses of galvanized iron wire to be laid over the backfilled, compacted and graded
banks. In case slope of the banks is 1:1 or more, bank protection shall be carried out
using gabions. Bank protection works shall be carried out by Contractor in accordance
with the drawings included in the CONTRACT. All materials required for such works
shall be supplied by Contractor and all works carried out in accordance with
specifications, approved drawings, instructions of Company and to the complete
satisfaction of Authorities having jurisdiction at no extra cost to Company.
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The length of the above protection shall be equal to the bank excavation and damage
and further extending 10 m on either sides. The width of the 'restoration on the slope
shall be determined by the levels:
-
2m above Highest Water Level, and
5m below Low Water Level or 60m along the slope from Highest Water Level,
whichever is the smaller.
8.3
Before final hydrostatic testing, Contractor shall "prove" the Diameter of the pipeline by
passing a gauging pig through the pipeline. The gauging pig shall be capable of locating
and detecting defects permitted by governing code. Contractor shall supply and install
all temporary scraper launchers receivers and other equipment, piping materials and
other consumables for the purpose.
9.0
POST-INSTALLATION HYDROSTATIC TEST

The complete water crossing must be tested immediately after the approved backfilling
of the trench. The test procedure shall result in a hoop stress in pipe corresponding to
90% SMYS of the pipe material. After temperature stabilisation, pressure shall be
retained in the pipeline for a minimum twenty four (24) hours and recorded by
manothermograph. The hydrostatic testing shall be carried out in accordance with
approved procedures.
10.0 POST-CONSTRUCTION SURVEY

After laying of the pipeline, Contractor shalI carry out a post-construction survey jointly
with Company. Any defects brought to the notice of Contractor shall be promptly
corrected by contractor at his own expense to the complete satisfaction of Company.
11.0 FINAL CLEAN-UP
After completion of construction, Contractor shall clear the site of all balance material
and debris. All balance pipe lengths, in case supplied by company, shall be returned to
Company's designated stock yard(s). Site shall be cleared to the complete satisfaction
of Company and Authorities having jurisdiction. All such works shall be done at no extra
cost to Company.
12.0 DOCUMENTATION
12.1
In addition to the documents specified elsewhere in this specification, Contractor shall

submit to the Company six copies of leach of the following documents/records.
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12.2
Complete record of pipes "taken-over" from Company, number of pipe lengths

used, and record of return of balance pipe length to Company's designated stock
yard(s)
Copies of the permits obtained from Authorities having jurisdiction for the
various works.
Records of Non Destructive Testing of welds.
Clearance certificates from the land owners and Authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline RoU and work areas.
After completion of construction, Contractor shall prepare and furnish six sets of copies
and two sets of reproducible of As-Built drawings for the crossings.
As-Built drawings shall be as a minimum, include the following information:
12.3
True profile of the bed and banks of water crossing along the pipeline after
backfilling
True profile of the pipeline as installed and depth of cover at top of pipe at 10 m
interval.
Location and angle of sag bends and over bends.
Cross section along the pipeline indicating nature and extent of backfill materials,
thickness of concrete coating to pipe etc.
Method and extent of bank protection.
All documents shall be in English language.
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FOR
PIPELINE CONSTRUCTION
(ONSHORE)
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1.0
SCOPE
1.1
This specification covers the minimum requirements for the various activities to be carried out
by Contractor for or about the construction of cross-country onshore pipelines.
1.2
The various activities covered in this specification include the following works of pipeline
construction:
-
Clearing, grubbing and grading of Right-of-Use;
Construction of all temporary facilities required in connection with the WORKS;
Staking of the pipeline route;
Handling, hauling, stringing and storing of all materials;
Trenching;
Field bending of line pipe;
Lining-up and Welding;
Pipeline laying;
Backfilling;
Tieing-in
Installation of auxiliary facilities and appurtenances forming a part of pipeline

construction;
Clean-up and restoration of Right-of-Use;
Maintenance during defects liability period.
1.3
This specification shall be read in conjunction with Scope of Work and requirements indicated in
specifications and documents included in the CONTRACT between Company and Contractor.
1.4
Contractor shall, with due care and diligence, execute the WORK in compliance with all laws, by
laws, ordinances, regulations etc. of the land 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 for the execution of the WORK, whether of a temporary or permanent nature.
1.5
Contractor shall take full responsibility for the stability, suitability and safety of all operations
and methods involved in the WORK.
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1.6
Contractor shall be deemed to have inspected, examined and independently obtained all
necessary information of WORK area(s) and its surroundings and shall have satisfied himself as
practicable to the form and nature thereof, including sub-surface conditions, hydrological and
climatic conditions, the extent and nature of the WORK and materials necessary for the
completion of the WORK, and the means of access to the WORK area(s).
1.7
Contractor shall be deemed to have obtained and understood all necessary information with
respect to risks, contingencies and all other circumstances, which may influence the WORK.
Any neglect/omission/failure on the part of Contractor in obtaining necessary and reliable
information for performance of WORK shall not relieve him from any liabilities or
responsibilities for completion of WORK.
1.8
Contractor shall, in connection with the WORK, provide and maintain at his own costs, all lights,
guards, fencing, watching etc., when and where necessary or required by Company or by any
duly constituted authority and/or by the authorities having jurisdiction thereof for the protection
of the WORK and properties or for the safety and the convenience of public and/or others.
1.9
Unless otherwise specified, all sections of this specification shall apply to all the specifications
2.0
2.1
Reference has been made in this specification to the latest edition of the following codes,
standards and specifications:
a.
API 1 104
Welding of Pipelines and Related facilities
b.
API 1105
Bulletin on Construction Practices for Oil and Products

Pipelines.
c.
ASMEB 31.4

and Other Liquids.
d.
ASME B 31.8
Gas Transmission and Distribution Piping Systems.
e.
OISD B 141
Design and construction requirements for cross-country

f.
Part 192, Title 49
Transportation of Natural and other Gases by Pipe Line

g.
Part 195

(US DOT - Pipe Line Safety Standards)
In case of conflict between the requirements of above mentioned codes, standards and practices,
the most stringent requirement shall govern. In case of conflict between the requirements of this
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specification and that of the above referred codes, standards and practices, the requirements of
this specification shall govern.
2.2
3.0
-
the words 'Should', 'May' and 'Will' are non-mandatory, advisory or recommended.
REQUIREMENT OF RIGHT OF USE AND ACCESS THERETO

Contractor shall, before starting and clearing operations, familiarize himself with all the
requirements of the Authorities having jurisdiction over the Right of Use (ROU) for WORK
along the pipeline route or in connection with the use of other lands or roads for construction
purposes.
Contractor shall notify Company well in advance during WORK progress, the method of
construction for crossing road, railway, pipeline, cable, canal, river and other existing obstacles.
Contractor shall not commence WORK on such crossings before having obtained approval from
the Authorities and landowners concerned to the satisfaction of Company. The crossings shall be
installed to meet at all times, the requirements and conditions of the permit(s) issued by the
Authorities concerned. In the absence of any specific requirements by Authorities, Contractor
shall comply wit11 Company's instructions.
The right of ingress and egress to the ROU shall be limited to points where such RoU intersects
public roads. Arrangements for other access required by the Contractor shall be made by him (at
his own cost and responsibility) and for such accesses the requirements of this specification shall
also apply.
Where the ROU comes within 30 meters of an existing line or facility, Contractor shall propose
and provide methods to safeguard the existing line or facility (e.g. a demarcation fence). No
work is allowed in such areas without Company's prior approval.
Where the ROU comes within the area of influence of high voltage electrical installations, the
following instructions shall be followed:
3.1
Instructions concerning high voltage influencing Safety measures during construction of

pipelines inside the area influenced by high voltage lines.
3.1.1 General
Pipelines, which are constructed inside the area of high voltage lines, may be electrically
influenced by these high voltage lines. The voltage caused by the influence may at times be so
high as to pose a danger to personnel working on the pipeline. It is imperative therefore, that the
instructions given below shall be accurately followed:
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3.1.1.1 It is a prerequisite that all personnel involved in construction of the pipeline, which is being
constructed in the area influenced by the high voltage system, must be given clear instructions on
safety measures to be taken while execution of WORK.
3.1.1.2 Vehicles and equipment must be earth-connected. This may be effected by attaching an
uninsulated cable or chain (which touches the ground) of adequate length to the underside of the
vehicle.
3.1.1.3 If it is not impossible for plant and/or materials to come to within 50m of the centre of the high
voltage system, special measures must be taken to prevent any approach beyond that distance,
unless Clause 3.1.2 is complied with.
3.1.1.4 DURING THUNDERSTORMS OR WHEN DISCHARGES ARE OBSERVED ON
INSULATORS ALL PERSONNEL MUST LEAVE THE AREA OF THE HIGH VOLTAGE
LlNE AND PIPELINE.
3.1.1.5 To prevent electrical voltages in a non-buried section of the pipeline from rising to dangerous
values, the length of the pipeline section which has been welded together before burial must not
exceed the length at which the maximum admissible voltage may be induced. This length shall
be calculated using an approved calculation method.
3.1.1.6 Before a pipeline section is lowered into the trench the structure's earth electrodes indicated in
the drawings or determined with calculation method must have been installed and connected
both to the pipeline section already buried and to the section, which is about to be buried. The
electrical connections, which serve the purpose of preventing dangerous voltages, must have a
min. area of 35 mm2.
Said connections must not be interrupted until after the permanent safety earth connections have
been installed and connected to the entire uninterrupted pipeline.
3.1.1.7 The welded connection between the pipeline section and the section already buried must be
installed at a distance of at least 50m from the nearest point of a pylon base.
3.1.1.8 Personnel doing WORK inside the area influenced by the high voltage system must wear
electrically insulating foot-wear (e.g. rubber knee boots) and wear insulating rubber or plastic
gloves.
3.1.2 Additional measures for WORK to be done at a distance less than 50m from the centre of
the high voltage system.
If WORK is to be done at a distance less than 50m from the centre of the high voltage system,
the measures indicated below must be complied with, in addition to the instructions specified in
clause 3.1.1.
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3.1.2.1 The WORK must not be started until agreement has been reached with the Authorities, which
control the high voltage system, about the implementation of the safety measures specified in
this section.
3.1.2.2 Measures must be taken to prevent excavating and hoisting equipment from approaching high
voltage lines to within any of the following distances.
This distance depends on the voltage carried. For individual connections the distance must be:
The measures taken may be as follows:

1.
Special selection of equipment, or limiting or blocking certain directions of movement, or

limiting the operational area, thereby mal<ing it definitely impossible for any WORK to be done
at a distance from the high voltage line of less than the accepted minimum.
2.
In case the measures recommended in 1. above are not feasible, installation of clearly visible
markers of sufficient height or laying out a 'no passage beyond this point' line of drums painted
bright red and white must prevent any WORK being done inside the danger area. Furthermore,
an inspector must be present all the time.
3.1.2.3 In the event that a vehicle, crane etc. should accidentally come into contact with a live cable of a
high voltage system or flash-over of electrical charge occurs, the driver must not leave his
vehicle because this will pose a serious threat to his life.
The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE.
The driver must not leave his vehicle until he has managed to leave the dangerous area, or
alternatively, when the Electricity Authorities have given notice that the cable(s) have been put
out of circuit. In case a serious fire starts in the vehicle, he is permitted to jump from the vehicle,
clearing it as far as possible, while the jump should possibly be to a dry spot.
4.0
RIGHT-OF-USE
The Contractor is required to perform his construction activities within the width of Right-ofUse (RoU) set aside for construction of pipeline, unless he has made other arrangements with the
land owner and/or tenant for using extra land. Variation in this width caused by local conditions
or installation of associated pipeline facilities or existing pipelines will be identified in the field
or instructed to the Contractor by Company.
The Right-of-Use boundary lines shall be accurately staked by the Contractor, so as to prepare
the strip for laying the pipeline.
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4.1
Stakings
Prior to clearing operations Contractor shall:
1.
Install Bench Marks, Intersection Points and other required survey monuments.
2.
Stake markers in the centerline of the pipeline at distances of maximum 100 metres for
straight line sections and maximum 10 metres of horizontal bends. Wherever RoU
centerline has been staked on ground, Contractor shall exercise care in accurately staking
the pipeline centerline, in consultation with Company.
3.
Stake two ROU markers at least at every 100 metres.
4.
Set out a reference line with respect to pipeline centerline at a convenient location.
Markers on reference line shall be at a distance of maximum 100 metres for straight line
sections and maximum 10 metres for horizontal bends.
5.
Install distinct markers location and indicating special points, such as but not limited to:
Contract limits, obstacle crossings, change of wall thickness, including corresponding
chainage, etc.
6.
Chainage markers shall be installed at every 250 meter
ROU Markers shall be staked out at the boundary limits of Right-of-Use wherever possible.
ROU Markers shall be painted red with numbers painted in white. Number shall be identical to
centerline marker number with letters A (left side) and B(right side) added, (looking to flow
direction). Reference markers shall also carry the same information as its corresponding
centerline markers.
Markers shall be of suitable material so as to serve their purpose and shall be coloured distinctly
for easy identification. Contractor shall be responsible for the maintenance and replacement of
the reference line markers until the permanent pipeline markers are placed and the as-built
drawings are submitted and approved.
Any deviation from the approved alignment shall be executed by Contractor after seeking
Company approval in writing prior to clearing operations.
4.2
Monuments
All shrines, monuments, border stones, stone walls and the like shall be protected and when
required, removed for safe keeping and replaced in original condition after construction as
directed by Company.
4.3
Fencing
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Prior to clearing and grading of the Right-of-Use or stringing of pipe, Contractor shall open
fences on or crossing the construction Right-of-Use and install temporary gates of sound
construction made of similar materials and suitable quality to serve purpose of original fence.
Adjacent posts shall be adequately braced to prevent slackening of the remainder of the fence.
Before such fences are cut and opened, Contractor shall notify"t11e land owner or tenant, and
where practicable, the opening of the fences shall be in accordance with the wishes of said owner
and tenant. In all cases where Contractor removes fences to obtain WORK room, Contractor
shall provide and install temporary fencing, and on completion of construction shall restore such
fencing to its original condition.
Contractor shall install temporary fencing on either side of ROU where in Company's opinion, it
is considered essential to ensure safety and non-interference, especially in areas like grazing
lands, villages etc.
Fencing shall be removable type wherever necessary, to permit crossing of traffic. The type of
fencing must be suitable for the situation in accordance with user. The pole distance shall not be
greater than 6m. The minimum height of the fencing shall be 1.2 in above grade. Fencing can
consist of one or more rows of smooth wire and/or of barbed wire.
Fencing shall be continuously maintained and the through-ways inspected to be shut during the
execution of the WORK.
4.4
ROU Clearing and Grading

Any obstacle, which may hinder the construction and laying of the pipeline all along the pipeline
route and for a strip of land of the size provided, shall be removed.
4.4.1 All stumps shall be grubbed on a continuous strip, with a width equal to trench top width plus
two meters on either side centered on the pipeline centerline. Further, all stumps will be grubbed
from areas of the construction Right-of-Use, where Right-of-Use grading will be required.
Outside of these areas to be graded and the mentioned trench strip, and at the option of
Contractor, the stumps may either be grubbed or cut off to ground level. Any stump cut off must
be left in a condition suitable for rubber-tyred pipeline equipment traffic.
4.4.2 All grubbed stumps, timber, bush, undergrowth and roots cut or removed from the Right-of-Use
shall be disposed off in a manner and method satisfactory to Company, land-owner and/or tenant,
and Government Authorities having jurisdiction and as soon as practical after the initial removal.
In no case shall it be left to interfere with the grading and laying operations. Whenever stumps
are grubbed and a hole is left in the ground, Contractor shall back-fill the hole and compact it to
prevent water from gathering in it and malting a big hole.
4.4.3 Contractor shall grade the pipeline Right-of-Use as required for proper installation of the
pipeline, for providing access to the pipeline during construction, and for ensuring that the
pipeline is constructed in accordance with the most up-to-date engineering and construction
practices.
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4.4.4 Contractor shall grade sharp points or low points, without prejudice to section 6.0 (trenching) of
this specification, to allow the pipe to be bent and laid within the limits set forth in these
specifications and drawings as regards the minimum elastic curvature permitted, and shall drill,
blast or excavate any rock or other material which cannot be graded off with ordinary grading
equipment in order to make an adequate working space along the pipeline.
4.4.5 No temporary or permanent deposit of any kind of material resulting from clearing and grading
shall be permitted in the approach to roads, railways, streams, ditches, drainage ditches and any
other position which may hinder the passage and/or the natural water drainage.
4.4.6 The Right-of-Use clearing and grading operations shall in no case involve embankment
structures of any type and class without prior approval of the authorities having jurisdiction over
the same.
4.4.7 In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other fill
materials, these shall be removed till stable natural ground level is reached so as to ensure the
construction of the pipeline ditch in stable ground.
4.4.8 In the case of Right-of-Use clearing and grading on the hillside or in steep slope areas, proper
barriers or other arrangement/structures shall be provided to prevent the removed materials from
rolling downhill. The Right-of-Use cross fall shall not exceed 10%. Slope of side hill faces shall
be stabilized to prevent landslides.
4.4.9 Wherever the pipeline Right-of-Use runs across, through or alongside farmyards, built-up areas,
groups of trees, forests, groves, horticultural spreads, gardens, grass-fields, ditches, dikes, roads,
paths, railways or any other area with restrictions of some kind, Contractor shall grade only the
width of the Right-of-Use necessary for digging the pipeline trench and constructing the pipeline.
In the said places Contractor shall carry out the works in such a way that damage resulting from
the pipeline construction is kept to a minimum.
4.5
Provision of detours
Contractor shall do all necessary grading and bridging at road, water and other crossings and at
other locations where needed, to permit the passage of its men and equipment. It is understood
that the Contractor has recognized such restrictive features of the Right-of-Use and shall provide
the necessary detours and execute the works without any extra cost to Company. Public travel
shall not be inconvenienced nor shall it be wholly obstructed at any point.
Contractor at his own cost shall furnish and maintain watchman detours, lanterns, traffic lights,
barricades, signs, wherever necessary to fully protect the public.
Contractor shall be responsible for moving its equipment and men across or around
watercourses. This may require the construction of temporary bridges or culverts. Temporary
bridging required for Right-of-Use crossing water courses shall be constructed in consultation
with concerned Authorities. Contractor shall ensure that such temporary works shall not interfere
with normal water flow, avoid overflows, keep the existing morphology unchanged and shall not
unduly damage the banks of water courses. No public ditches or drains shall be filled or bridged
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for passage of equipment until Contractor has secured written approval of the Authorities having
jurisdiction over the same. Contractor shall furnish Company a copy of such approval.
4.6
Steep and rocky terrain

Grading operations could normally be carried out along the Right-of-Use with mechanical
excavators or manually. In certain areas, grading may have to be resorted to exclusively by
blasting.
In rough or steep terrain, Contractor may have to grade access roads and temporary bypass roads
for its own use. Where such access roads do not fall on the Right-of-Use, Contractor shall obtain
necessary written permission from land owners and tenants and be responsible for all damages
caused by the construction and use of such roads, and at no extra cost to Company.
Wherever rocky terrain is encountered, grading shall be carried out in all types of solid rocks
which cannot be removed until loosened by blasting, drilling, wedging or by other recognized
methods of querrying solid rocks.
Where use of explosives is required in connection with Right-of-Use grading and trenching,
Contractor shall comply fully with requirements of the use of explosives as provided under
clause 6.3 of this Specification and as provided under "Rules for Blasting", as per Specification
for Blasting issued for this purpose.
4.7
Off Right-of-Use Damages

Contractor shall confine all its operations within limits of the Right-of-Use. Any damage to
property outside RoU shall be restored or settled to the Contractor's account.
Contractor shall promptly settle all off Right-of-Use damage claims. Should Contractor fail to do
so, Company shall give written notice to Contractor that if Contractor does not settle such claims
within seven days after such notice, Company shall have the authority to settle claims from the
account of Contractor.
5.0
HANDLING, HAULING, STRINGING AND STORING OF MATERIALS
5.1
General
The Contractor shall exercise utmost care in handling line pipe and other materials. Contractor
shall be fully responsible for all materials and their identification until such time that the pipes
and other materials are installed in permanent installation. Contractor shall be fully responsible
for arranging and paying for temporary storage areas for the pipeline materials, however, method
of storage shall be approved by Company.
Contractor shall reimburse the Company for the cost of replacement of all Company supplied
materials damaged during the period in which such materials are in the custody of the
Contractor. It shall be Contractor's responsibility to unpack any packings for the materials
supplied by Company.
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Pipe bevel protectors shall always be kept in position during all handling, transportation and
stringing operations and shall be removed only prior to fit-up for welding. After fabrication and
welding, the Contractor shall arrange to return all such bevel protectors at Company's designated
storage yard and as instructed by Company.
5.2
"Taking-over" of line pipe

The following stipulations shall apply in case CONTRACT provides for supply of line pipe, bare
and/or corrosion coated, by Company.
Contractor shall receive and 'take over' against requisition, line pipe from the Companys
designated place(s) of delivery as defined in the CONTRACT. Contractor shall perform visual
inspection of the bare pipes and coating of the corrosion coated pipes, as the case may be, in the
presence of Company and all damages shall be recorded. In the case of corrosion coated pipes
Contractor at his option may carry out holiday detection at a prescribed set voltage and record
such holidays, in the presence of Company, at the time of 'taking over'. HOWEVER, if
Contractor proposes to perform only visual inspection of coating, then repair of all holidays
found at the time of laying the pipeline shall be carried out by the Contractor at no extra cost to
Company. The Contractor shall be entitled to extra compensation for repair and rectification of
defects recorded at the time of 'taking over' as per the rate set fort11 in the "CONTRACT".
Repair of all damages occurring after taking over the delivery of the materials shall be to the
Contractor's cost. In case of delays in handing over of Company supplied materials, Contractor
shall be fully responsible for stopping and rearranging means of transportation at no extra cost to
Company.
5.3
Handling and hauling of line pipe
5.3.1
Bare pipes
Contractor shall unload, load, stockpile and transport the bare pipes using suitable means and in
a manner to avoid denting, flattening, or other damages to pipes. Pipe shall not be allowed to
drop or strike objects, which will damage the pipe but shall be lifted or lowered from one level to
another by suitable equipment. Lifting hooks when used, shall be equipped wit11 a plate curved
to fit the curvature of the pipe. In loading pipe on trucks each length shall be lowered to position
without dropping and each succeeding length shall rest on special supports on the truck and shall
be separated from the adjacent pipes. After loading, suitable chains and padding shall be used to
tie the load securely to each bolster. Pipe, when stock piled, shall be placed on suitable skid to
keep it clear of the ground and flood water. Care shall be exercised in handling or stock-piling
pipes in order to avoid distortion, flattening, denting or other damages. The Contractor shall
provide all necessary timber or other materials required for the stock-piling. While stacking, the
number of allowable layers of bare pipes shall be calculated as per API RP 5L1 and shall be
agreed with Company. The stacks must be properly secured against sliding and shall consist of
pipes of the same diameter and wall thickness. Adjacent stacks of pipes having different
dimensional characteristics shall be clearly separated.
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Pipes which are damaged at the time of delivery or 'taking-over' (when line pipe is supplied by
Company), particularly those which are dented, buckled, or otherwise permanently deformed,
must be stacked separately and may be transported to the sites only when these defects have been
repaired or eliminated.
5.3.2
Corrosion coated pipes

The Contractor shall load, unload, transport and stockpile the coated pipes using approved
suitable means and in a manner to avoid damage to the pipe and coating. Contractor shall submit
to Company a complete procedure indicating the manner and arrangement used for handling and
stacking of coated pipes for Company approval prior to commencement of handling operations.
Use of vacuum lifting equipments is preferred. Hooks may also be used for handling the pipes
provided they have sufficient width and depth to fit the inside of the pipe and covered with soft
material like rubber, Teflon or equivalent, so as not to cause damages to bevel or pipe ends.
During hoisting cables/wire ropes shall have sufficient inclination compared to pipe axis so that
they do not come into contact with external coating.
Coated pipes may be handled by means of slings and belts of proper width (minimum 60 mm)
made of non-metallic/non-abrasive 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.
During handling, suitable handling equipments with proper length of booms shall be used.
Forklifts may be used provided that the arms of the forklifts are covered by suitable pads
preferably rubber. Before lifting operations, it is essential to ensure that the pipe surface is free
from foreign materials with sharp edges. Belts/slings when used shall be cleaned to remove hard
materials such as stone, gravel etc. Coated pipes shall not be bumped against any other pipe or
any other objects. Rolling, skidding or dragging shall be strictly forbidden.
Coated pipes at all times shall be stacked completely clear from the ground 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.
The 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, for
example, consist of dry, germ free straw with a 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,
particularly in case of small diameter pipes with low wall thickness. The pipes shall be stacked
so that the uncoated bevelled ends are in line at one end, thus making differences in lengths
clearly noticeable.
Stacks shall consist of limited number of layers so that the pressure exercised by the pipes own
weight does not cause damages to the coating. 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 bead of
pipes shall be positioned in such a manner so as not to touch the adjacent pipes.
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Coated Pipes stacked in open storage yards/dump yards shall be suitably covered on top to
decrease direct exposure to sunlight.
The ends of the pipes during handling and stacking shall always be protected with bevel
protectors.
The trailers/rail wagons shall be equipped with adequate pipe supports having as many round
hollow beds as the number of pipes to be placed on the bottom of the trailer bed. Supports shall
be provided for at least 10% of the pipe length. 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 shall be free from all nails and staples where pipes are in contact. The second layer
and all subsequent layers shall be separated from each 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 trailers/rail wagons 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 convex portions such as reinforcement of the truck/rail wagon body, rivets etc. to
prevent damage to the coated surface.
5.4
Stringing of pipe
Pipes shall be unloaded from the stringing trucks and lowered to the ground by means of Side
boom/Hydra crane tractor or swinging crane or other suitable equipment using lifting devices as
mentioned earlier. Dragging or sliding of pipe shall not be permitted. Special precaution shall be
taken during stringing of corrosion coated pipes as per the special requirements of previous Para.
Stringing of pipe shall only be carried out in daylight and after clearing and grading operations
have been completed. Pipe shall not be strung on the Right-of-Use in rocky areas where blasting
may be required, until all blasting is complete and the area cleared of all debris.
The stringing of the pipe on the Right-of-Use shall be done in such a manner as to cause the least
interference with the normal use of the land crossed and to avoid damage to or interference with
the pipes. The sequence of pipes must be interrupted at suitable intervals, spaced to coincide with
passages, roads, railways and water-courses crossings as well as at other places if requested by
land Owner or tenants to permit use of the land. Also care shall be taken to provide safe working
space between trench edge and the pipe. Pipe shall be strung on approved soft earth/sand filled
bags and wedge. Bottom of pipe shall in no way touch the ground. There shall be sufficient
clearance from bottom of pipe & the ground level. The pipe shall be supported at minimum two
locations.
In case line pipe supply is by different Manufacturers, Contractor shall string all line pipe of one
Manufacturer before commencing the stringing of the line pipe of another Manufacturer.
When parallel pipelines are being constructed, bumping against and contact with the strung
sections of pipe shall be avoided, whether the stringing of the pipes for the individual lines is
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carried out separately or simultaneously. When parallel pipes of different sizes are to be laid, the
pipe stringing shall suit the respective location of pipes in the trench.
The pipe lengths must be properly spaced in order to make easier the handling during the
welding phase.
It shall be the responsibility of the Contractor to see that pipe is strung in accordance with the
approved drawings for the proper placement of pipe by size, thickness, grade and other
specifications. Any additional handling of pipes resulting from failure to, comply with these
requirements shall be at the Contractor's expense.
5.5
Repair of damaged pipes

After the pipe has been strung on the Right-of-Use, it shall be inspected by the Contractor and
the Company and all defective pipe ends repaired. Defective pipes shall be repaired or rejected as
the Company may direct as per the requirements of clause 5.2 of this Specification.
5.6
Materials other than linepipe

Contractor shall receive and take over against requisition all Company supplied materials from
Company's designated place(s) of delivery as defined in the CONTRACT. Contractor shall
perform visual inspection and defects, if any noted, shall be recorded separately. The Contractor
shall be entitled to extra compensation for repair and rectification of such defects at the rates set
forth in the 'CONTRACT".
The Contractor shall perform the necessary loading, unloading, hauling from points designated
by the Company and storing, if necessary, of all materials. The Contractor shall exercise care in
handling, hauling, storing and distribution of materials in order to avoid damage and
deterioration of these materials and prevent their theft or loss.
Materials excluding line pipe shall be stored in sheltered storage. Such materials shall not be
strung on the Right-of-Use but shall be transported in covered conveyances for use only at the
time of installation.
Contractor shall ensure that all valves and whenever applicable, other materials are fitted with
suitable end covers of the type approved by Company. Materials with worked surfaces such as /
flanges, pipe fittings, etc. must be stacked and handled so as to avoid contact with the ground or
with substances that could damage them.
The Manufacturer's instructions regarding temperature and procedure for storing materials,
which are subject to alteration of the original properties and characteristics due to unsuitable
storage, must be strictly complied with and, if required, an adequate heat conditioning shall be
provided for these materials.
When material is supplied in containers and packages, it must not be thrown or dropped, nor
handled using hooks which could damage the container or the materials, either during
loading/unloading or during successive handling, until their final use.
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Coating materials, 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. These materials shall be kept permanently in store, supported
above the ground in a dry place protected against the weather and transported for use only at the
time and in the quantities necessary for immediate application. Deteriorated materials shall not
be used and replaced with no extra cost to Company.
5.7
Identification
Contractor shall provide all pipes, bends etc. greater than 50mm NB with serial numbers as soon
as possible upon the receipt of such materials at site and measure their length and state it on the
pipes, etc. Pipes to be bent shall be measured prior to bending. Identification (i.e. letter, number
and length) shall be indelible.
All serial numbers shall be recorded in a list, which shall also state appurtenant pipe numbers.
Beside recording the stamped pipe numbers, length of pipe and painted-on serial numbers, the
stamped-in numbers of T-pieces, bends, valves, etc. and the batch numbers of bends, T-pieces,
valves, etc and the make of valves, shall also be recorded in said list.
Before a pipe length, pipe end, etc is cut, the painted serial number and stamped-in pipe number
shall be transferred by Contractor in the presence of Company to either side of the joint, which is
to be made by cutting, and the changes shall be recorded in the above mentioned list stating the
(new) length. The result shall be such that all pipes, pups, etc. of diameter greater than 501mm
NB bear clear marks painted on.
Contractor shall explicitly instruct his staff that parts which cannot be identified must not be
removed, except after permission by Company.
As a general rule parts shall be marked as described above before being moved. In no conditions
may unmarked parts be incorporated into the WORK.
6.0
TRENCHING
6.1
Location
Contractor shall excavate and maintain the pipeline trench on the staked centerline of the
pipeline taking into account the curves of the pipeline.
In case of common ROU, the centerline of the trench shall be established from the location of
existing pipeline. In case of independent ROU, the centerline of the trench shall be established
from the edge of ROU.
6.2
Excavation
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6.2.1 Contractor shall, by any method approved by Company, dig the pipeline trench on the cleared
and graded Right-of-Use. In cultivable land and other areas specifically designated by the
Company, top 300mm of the arable soil on the pipeline trench top width shall be excavated and
stored separately, to be replaced in original position, after backfilling and compacting rest of the
trench.
Suitable crossings shall be provided and maintained over the open RoU, where necessary, to
permit general public, property owners or his tenants to cross or move stock or equipment from
one side of the trench to the other.
Care shall be exercised to see that fresh soil recovered from trenching operation, intended to be
used for backfilling over the laid pipe in the trench, is not mixed with loose debris or foreign
material. The excavated material shall never be deposited over or against the strung pipe.
6.2.2 In steep slope areas or on the hillside, before commencing the works, proper barriers or other
protection shall be provided to prevent the removed materials from rolling downhill.
6.2.3 On slopes wherever there is danger of landslide, the pipeline trench shall be maintained open
only for the time strictly necessary. Moreover, the Company may require manual excavation of
trench, local route detouring and limiting the period of execution of the works. The Contractor
shall make adequate arrangements for safe working of the personnel involved in manual
excavation of trench.
6.2.4 In certain sloppy sections, before the trench cuts through the water table, proper drainage shall be
ensured both near the ditch and the Right-of-Use in order to guarantee soil stability.
6.2.5 All sewers, drain ditches and other natural waterways involved in the execution of the works
shall be maintained open and functional. The same applies to canals, irrigation canals, and
pipelines and buried facilities crossed by the ditch for which temporary pipelines shall be laid, if
required, and proper temporary installations provided.
6.3
Blasting
Blasting for trenching and the related removal of scattered rock and debris caused by the blasting
from the Right-of-Use and/or adjacent property, shall be performed by Contractor as part of his
WORK.
Every possible precaution shall be taken to prevent injuries and damages to persons and
properties during blasting operations, which shall be performed in accordance with Rules for
Blasting in Standard Blasting Specification issued for the purpose.
6.3.1 All necessary precautions shall be taken to prevent stones from falling outside the Right-of-Use
and in cultivated areas and to avoid any damage to the installations and properties existing
nearby.
6.3.2 Blasting and removal of debris shall be carried out prior to stringing the pipes.
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6.3.3 Company reserves the right to refuse blasting where possible danger exists to property, existing
utilities or other structures. In such locations other methods of extracting rock shall be proposed
by Contractor and shall be approved by Company.
6.4
Normal cover and trench dimensions

The trench shall be excavated to a minimum width so as to provide, on both sides of the installed
pipeline, a clearance as indicated in the job standards/drawings and to a depth sufficient to
provide the minimum cover as indicated below. The dimensions in the table below shall govern
except as noted herein or as shown on the job standards or detailed construction
document/drawings or as required by authorities having jurisdiction, whichever is greatest.
Minimum depth of cover shall be measured from the top of pipe corrosion/concrete weight
coating (as applicable) to the top of undisturbed surface of the soil or top of graded working strip
or top of road or top of rail whichever is lower. Fill material in working strip shall not be
considered to add to the depth of cover. However, surface of fill material placed to fill hollows
may be used to determine the depth of cover subject to prior approval by Company.
Location
Minimum Cover in meters
a)
Industrial, Commercial & Residential Area
1.0
b)
Rocky Terrain
1.0
c)
Minor water crossing/canals/drain/nala/stream
1.5
d)
River crossings for which scour depth is defined

(below scour)
1.5
e)
River crossings (Bank width < 501n)

(below lowest bed level)
1.5
f)
Other River crossings (Bank width > 5011-1)

2.5 (for normal soil)

1.5 (for rocky strata)
g)
Water crossing by HDD

2.5
h)
Uncased/Cased Road Crossing/Station approach
1.2
i)
Railways crossing
1.7
j)
Drainage, ditches at roads/railway crossings
1.0
k)
Marshy land and creek area
1.5
Notes:
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In case pipeline is located within 15 m from any dwelling unit, the cover shall be increased by
300 mm over and above that specified.
6.5
Cutting and removal of paving

Whenever it is permitted by Authorities and/or Company to open cut a paved road crossing, or
where the line is routed within the road pavement, Contractor shall remove the paving in
accordance wit11 the restrictions and requirements of the Authorities having jurisdiction thereof
or as directed by Company. The open cut for the road crossing shall be carried out only when the
section of pipeline to be laid is complete. After laying the pipeline, backfilling shall be
immediately performed and all the area connected with the works shall be temporarily restored.
Throughout the period of execution of such works, Contractor shall provide and use warning
signs, traffic lights or lanterns, barricades, fencing, watchman, etc. as required by the local
authorities having jurisdiction and/or Company.
For all roads, paths, walkways etc., which are open-cut, Contractor shall provide temporary
diversions properly constructed to allow the passage of normal traffic with the minimum of
inconvenience and interruptions.
The paving shall be restored to its original condition after the pipeline is installed.
6.6
Extra depth and clearance

At points where the contour of the earth may require extra depth to fit the minimum radius of the
bend as specified or to eliminate unnecessary bending of the pipe according to customary good
pipeline practice, or where a deep trench is required at the approaches to crossings of roadways,
railroads, rivers, streams, drainage ditches, and the like, Contractor shall excavate such
additional depth as may be necessary at no extra cost to the Company.
Contractor shall excavate to additional depth where the pipeline approaches and crosses other
pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground
structures, so that the pipeline may be laid with at least 50 centimeters free clearance from the
obstacle or as specified in the drawings, or such greater minimum distances as may be required
by authorities having jurisdiction.
Where the pipeline crosses areas, whose easements specifically require greater than normal
depths of cover, the trench shall be excavated to extra depth in accordance with the Right-of-Use
Agreements or as required.
Contractor shall excavate all such additional depths as may be necessary at no extra cost to the
Company.
6.7
Grades, Bends and Finish of trench

The trench is to be cut to a grade that will provide a firm, uniform and continuous support for the
pipe. Bends shall be made in the pipe at significant changes in grade of the trench. Company
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reserves the right to set the grade of the trench and locate the bends if so desired, in which case
Contractor shall excavate, at no extra cost, the trench and bend the pipe to such a grade.
Company desires reduce to a minimum the required number of cold field bends to lay the pipe to
conform to the general contour of the ground and maintain a normal cover. This can be
accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually
deepening the trench in approaches to crossings. Such trenching WORK shall be done by
Contractor at no extra cost to the Company.
Company intends that there will be a minimum of hand grading of the trench bottom. However,
to achieve this, Contractor will have to dig as square a bottom of the trench as possible with the
equipment. This in part can be obtained by adjusting and adopting the crumbing shoe and
digging teeth of the trenching machines and by use of a drag behind the trenching machines or
manually dressing-up the same. Contractor shall do such hand WORK in the trench as is
necessary to free the bottom of the trench from loose rock and hard clay and to trim protruding
roots from the bottom and side walls of the trench.
6.8
Padding
In all cases where rock or gravel or murum/hard soil is encountered in the bottom of the trench,
Company will decide the exact extent of trench padding, that will be required. The thickness of
the compacted padding shall not be less than 150mm. In those areas that are to be padded, the
trench shall be at least 150snm deeper than otherwise required, and evenly and sufficiently
padded to keep the pipe, when in place, at least 150mm above bottom of excavated trench.
Acceptable padding shall be placed under the pipeline before its installation, and around after
installation to establish at both sides and on top of the pipe a permanent layer of padding. The
thickness of compacted padding on top of pipe corrosion coating shall be at least 150mm.
Padding materials that are approved by Company shall be graded soil/sand and/or other materials
containing no gravel, rock, or lumps of hard soil. Sand used for padding shall pass through sieve
size ASTM C33 No. 16.
6.9
Protection of trench
Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be
made to the Company by reason of its caving either before or after pipe is laid.
All lumber, sheet-piling jacks or other materials that may be necessary to shore the trench, in
order to prevent caving are to be furnished and removed by Contractor.
Contractor shall dewater if necessary, using well point system/concrete grouting for stabilization
of trench wall or other suitable systems, shore or do what else might be required to excavate the
trench, install the pipe in it and backfill the trench in accordance with the specifications at no
extra cost to Company.
6.10
Protection of underground utilities and special methods
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Available details of underground utilities, as far as acquired by Company, shall be indicated in

the Drawings. However, Contractor shall obtain plans and full details of all existing and planned
underground services from the relevant Local Authorities and shall follow these plans closely at
all times during the performance of WORK. Contractor shall be responsible for location and
protection of all underground lines and structures. In special locations the use of trenching
machine/backhoe may result in damage to property and subsurface structures likely to be
encountered during excavation. At such places, Contractor shall excavate the trench manually to
same specification at no extra cost.
Where the pipeline crosses other underground utilities/structures, the Contractor shall first
manually excavate to a depth and in such a manner that the utilities/structures are located.
Temporary under pinning or any other type of supports and other protective devices necessary to
keep the interfering structure intact shall be provided by the Contractor at his own cost and shall
be of such design as to ensure stability & safety against their possible failure.
Despite all precautions, should any damage to any structure/utility etc., occur, the
Owner/Authority concerned shall be contacted by the Contractor and repair shall forthwith be
carried out by the Contractor at his expense under the direction and to the satisfaction of
Company and the concerned Owner/Authority. If Contractor fails to repair in reasonable time,
Company reserves the right to have the repair executed at the cost of the Contractor.
6.11
Encroachments and working near other utilities

In locations, where pipeline has to be laid in the body of a road, canal, dyke or other locations
under jurisdiction of Government/Public Bodies, the Contractor shall perform such WORK
without extra compensation, according to the requirement of concerned Authorities. When it
becomes necessary that Contractor has to resort to hand digging, well point, erection of sheet
piling or any other special construction method in these areas, no extra compensation shall be
paid. Contractor shall contact the Authorities concerned in order to become familiar with their
requirements. The facilities damaged during construction shall be restored to their original
condition to the satisfaction of Company/Authority.
In locations, where the pipeline has to be laid more or less parallel to an existing pipeline, cable
and/or other utilities in the Right-of-Use, Contractor shall perform the WORK to the satisfaction
of the Owner/Authority of the existing pipeline/cable/utility. In such locations Contractor shall
perform WORK in such a way that even under the worst weather and flooding conditions, the
existing pipeline/utilities remain stable and shall neither become undermined nor have the
tendency to slide towards the trench.
Contractor shall be liable for any damage occurring to, or resulting from damage to other
pipelines, underground structures/utilities, as laid down in clause 6.10 of this specification.
6.12
Provisions for negative buoyancy to the pipe

Contractor shall check if up-floating danger is present in open trench and then shall take
appropriate measures to prevent up-floating such as applying soil dams and dewatering of trench
or temporary filling of water into the line (in exceptional cases).
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In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall be drained
to the extent and for the time required to make a visual inspection of the ditch bottom. After this
inspection, the presence of water will be allowed provided its level does not cause sliding of the
ditch sides and pipe floating before backfilling when no concrete weighing is provided.
The water pumped out of the ditch shall be discharged into a natural water course.
Whenever up-floating of the pipeline after backfilling is to be reckoned with, anti-buoyancy
measures shall be provided by Contractor for such areas of construction, using one or a
combination of the following methods:
-
weighing by applying a continuous concrete coating around the pipe;
weighing by installing gravel filled Geotextile bags/Saddle weight;
installing metal anchors screwed into the subsoil in pairs;
deeper burial of pipeline;
provision of select backfill material.
The above provisions shall be in accordance with the relevant specifications and/or job
standards/drawings.
Contractor shall indicate the option(s) selected to Company for review and approval along with
calculations, wherever applicable.
7.0
BENDING
Contractor shall preferably provide for changes of vertical and horizontal alignment in pipeline
by malting elastic bends. Contractor may provide cold field bends, at its option for change of
direction and change of slope. Company at its option, may authorise fabricated bends for
installation at points where in Company's judgment the use of such bends is unavoidable.
Overbends shall be made in such a manner that the centre of the bend clears the high points of
the trench bottom. Sag bends shall fit the bottom of the trench and side bends shall conform and
leave specified clearance to the outside wall of the trench.
7.1
Elastic bends
The minimum allowable radius for elastic bends in the buried pipeline including that for
continuous concrete weight coated pipe shall be in accordance with relevant job standards. The
elastic bend shall be continuously supported over its full length. A radius smaller than permitted
in elastic bending shall require a cold bend.
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7.2
Cold field bends
7.2.1 The radius of cold field bends shall not be less than 40 times the pipe specified diameter for pipe
diameters 18 inch and above and shall not be less than 30 times the pipe specified diameter for
pipe diameter less than 18 inch.
7.2.2 Contractor shall use a pipe bending machine of adequate capacity and employ recognized and
accepted methods of bending of coated pipe in accordance wit11 good pipeline construction
practice. However, bending machines shall be capable of making bends without wrinkles,
buckles, stretching and with minimum damage to the coating.
7.2.3 Contractor shall, before the start of the WORK, submit and demonstrate to Company a bending
procedure, which shall conform to the recommendations of the manufacturer of the bending
machine. The procedure shall include amongst other steps- lengths, maximum degree per pull
and method and accuracy of measurement during pulling of the bend. The bending procedure
and the equipment used shall be subject to Company's approval.
7.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane passing
through the neutral axis of the bend, which shall be installed positioning the longitudinal weld in
the upper quadrants. If horizontal deviations are to be achieved by joining more adjacent bends,
the bending of the pipe lengths shall be made by positioning the longitudinal welds alternatively
70mm above and below the plane passing through the neutral axis in such a way that the bends
are welded with the longitudinal welds displaced by about 150 mm and situated in the upper
quadrants. In case of vertical bends formed from a number of pipe lengths, the longitudinal
welds shall be positioned on the plane passing through the neutral axis of the bend to the right
and left alternatively.
7.2.5 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to avoid
damage to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller
type bending machines are preferred.
7.2.6 The ends of each bent length shall be straight and not involved anyway in the bending. The
length of the straight section shall permit easy joining. In no event shall the end of the bend be
closer than 1.5 m from the end of a pipe or within one meter of a girth weld.
7.2.7 The ovalization caused on each pipe by bending shall be less than 2.5% of the specified diameter
at any point. Ovalization is defined as the reduction or increase in the internal diameter of the
pipe compared with the nominal internal diameter. A check shall be performed on all bends in
the presence of Company Representative by passing a gauge consisting of two metallic discs
with a diameter equal to 95% of the nominal internal diameter of the pipe connected rigidly
together at a distance equal to 300 mm.
7.2.8 The wall thickness of finished bends, taking into account wall thinning at the outer radius, should
not be less than the design thickness. An indication of wall thinning as a percentage is given by
the following empirical formula:
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50
Wall Thinning = __________
(n+1)
Where 'n' is the inner bend radius divided by pipe diameter. Pipes with measured wall thickness
greater than the nominal wall thickness (i.e. with +ve tolerance) shall normally be used for
making cold field bends.
7.2.9 Cold bend pipes on site shall have the corrosion coating carefully checked with the aid of a
holiday detector for cracks in the coating down to the pipe wall. It must also be checked whether
the coating has disbonded from the pipe wall during bending by beating with a wooden mallet
along the outer radius. Any defects or disbonding of the coating caused during bending (also
forced ridges in the coating) shall be repaired at the Contractor's expense in accordance with
Company approved procedures.
7.2.9 When pipelines are laid in parallel, the horizontal bends shall be concentric.
7.3
Miter and unsatisfactory bends

All bends showing buckling, wrinkles, cracks or other visible defects or which are in any way in
disagreement, in whole or in part, with this specification shall be rejected.
No miter bends shall be permitted in the construction of the pipe line. Contractor shall cut out
and remove any bend or bends, which do not meet the specifications and shall replace the same
with bends complying with specification at no additional cost to the Company. In the event the
CONTRACT provides for supply of line pipe by Company, the pipes required for replacement
will be furnished by Company, but the cost of replacement of such pipes shall be borne by
Contractor.
Cutting of factory made bends and cold field bends for any purpose are not permitted.
8.0
LINING UP & WELDING

Each length of pipe shall be thoroughly examined internally and externally to make sure that it is
free from visual defects, damage, sever corrosion (sea water pitting), dirt, animals or any other
foreign objects. Each length of the pipe shall be adequately swabbed, either by use of canvas belt
disc of proper diameter, or compressed air blowing or by other methods approved by the
Company. Damaged/corroded pipes shall be kept separate. Each length of pipe shall be pulled
through just before being welded.
All rust and foreign matters shall be removed from the beveled ends by power operated brush.
This shall be affected inside & out side and for a minimum distance of 25 mm from edge of
bevel. The bevel shall be thoroughly inspected at this stage. Should laminations, spilt ends or
manufacturing defects in the pipe observed, the length of the pipe containing such defects shall
be removed from the line in accordance with relevant specification.
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Contractor shall align and weld together the Joints of pipe so as to construct a continuous
pipeline. All welds in the pipeline made by Contractor shall be of strength equal to that of pipe.
All welding shall conform to Company's welding specifications enclosed with the Contract.
8.1
Pipe defects and repairs

It is Contractor's responsibility to repair all internal and/or external defects.
8.1.1 Acceptability of defects in the pipe detected during inspection at the WORK site shall be
determined in accordance with latest edition of Company's own material specification or code
ASME B31.8 / B 31.4 whichever is more stringent.
8.1.2 The maximum permissible depth of dents in pipes shall be as per applicable linepipe
specification issued by Company.
8.1.3 Dents, which contain a stress concentrator such as scratch, gauge, arc burn or groove, and dents
located at the longitudinal, spiral or circumferential weld shall be removed by cutting out the
damaged portion of pipe as a cylinder.
8.1.4 Repair on line pipe shall be executed as specified in Company's material specification or Code
ASME B 31.8 / B 31.4, whichever is more stringent. A record of all repairs shall be maintained
by Contractor. This record, provided with the pipe identification number shall be submitted to
the Company.
8.1.5 If due to cutting or repairs, the pipe identification number is removed, it shall be reprinted
immediately by Contractor in the presence of Company. In the event, the CONTRACT provides
for supply of line pipe by Company, Contractor shall be charged for any pipe length due to loss
of identification number. No pipe without identification number shall be transported and/or
welded into the pipeline.
8.1.6 Repair of damaged pipe ends by hammering and/or heating is not allowed. If the dented area is
minor and at least 200 mm away from the pipe end, and the steel is not stretched, severed, or
split in the Company's opinion, the pipe may be straightened with a proper jack.
8.2
Pipe handling and skid spacing
8.2.1 When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings approved by
Company shall be used. Contractor shall submit his method of skidding and skid spacing for
Company's approval. A strip of soft material shall be placed in between skid and pipe to protect
the external coating of the pipe. The material shall be approved by the Company.
8.2.2 The maximum skid spacing is not allowed before the stringer 'bead and the top and bottom
reinforcements are completed, provided that the distance between the incomplete weld and the
skid shall not exceed 9 (nine) percent of the skid spacing.
8.2.3 Skids shall be at least 1.20 meter long. For pipe with an O.D. of 324 mm and larger the skids in
contact with the pipe shall have a width of at least 200 mm. For pipe with an O.D. of less than
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324 mm the skids in contact with the pipe shall have a width of at least 150 mm. Pipe supports
shall be stable, so that pipe movement will not cause the supports to move. Skids shall not be
removed under a string before lowering in. The welded pipe shall be maintained on skids at the
minimum distance of 500 mm above ground. Crotches shall be installed at frequent intervals (at
least every l0th support) with a greater number required at bends and undulating grounds.
8.3
Night caps
At the end of each day's WORK or every time when joining and welding operations are
interrupted, the open ends on the welded strings of pipes shall be capped with a securely closed
metal cap or plug as approved by Company so as to prevent the entry of dirt, water, or any
foreign matter into the pipeline. These covers shall not be removed until the WORK is to be
resumed. The caps/plugs used shall be mechanical type and shall not be attached to pipe by
welding or by any other means, which may dent, scratch or scar the pipe.
8.4
Temporary caps
Whenever the welded strings of pipes are left open at intervals to be tied in later after an
appreciable time lag, under roads, railroads, rivers, marshy crossings, etc., temporary caps
approved by Company shall be welded to the ends of the pipe.
9.0
LAYING
9.1
Lowering in trench
9.1.1 Lowering can start after removal from ditch bottom of all off cuts, pipe supports, stones, roots,
debris, stakes, rock projections up to 15 cm below underside of pipe and any other rigid materials
which could lead to perforation or tearing of the coating. Sand padding, graded soil and/or other
materials containing no gravel, rock shall be provided as required in accordance with clause 6.8
of this specification in such a way to get an even surface for pipe laying.
9.1.2 Lowering shall follow as soon as possible, after the completion of the joint coating of the welded
pipe string In the case of parallel pipelines, laying shall be carried out by means of successive
operations, if possible without interruption.
9.1.3 Before lowering in, a complete check by a full circle holiday detector for pipe coating and for
field joint coating shall be carried out and all damages repaired at Contractor's cost. All points on
the pipeline where the coating has been in contact with either the skids or with the lifting
equipment during laying, shall be carefully inspected for damages, denting or other defects and
shall be completely repaired. If, after checking, it becomes necessary to place the pipeline again
on supports at the bottom of the trench, these must be padded in such a way as to prevent damage
to the coating, thus avoiding necessity for further repairs when the pipe is finally raised and laid.
Before the last operation, a check must be made of the coating at points of contact with the
supports.
9.1.4 Before lowering in, short completed sections of the pipeline shall be cleaned with compressed air
driven cup Pig or Foam pig in order to remove all dirt, etc. from the inside of pipe sections. In
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case such cleaning is proposed by Contractor after lowering, the Contractor shall obtain approval
from the Company.
9.1.5 The pipeline shall be lifted and laid using, for all movements necessary, suitable equipment of
non-abrasive material having adequate width for the fragility 'of the coating. Care shall be
exercised while removing the slings from around the coated pipe after it has been lowered into
the trench. Any damage caused to the coating shall be promptly repaired. Lowering-in utilizing
standard pipe cradles shall be permitted if Contractor demonstrates that pipe coating is not
damaged. No sling shall be put around field joint coating.
9.1.6 Wherever the pipeline is laid under tension, as a result of an assembly error (for example,
incorrect positioning of bends, either horizontal or vertical), the trench shall be rectified or in
exceptional cases a new assembly shall be carried out, to be approved by Company, so that it fits
the excavation and the laying bed.
9.1.7 Laying shall be carried out under safe conditions so as to avoid stresses and temporary
deformations of the equipments, which may cause damage to the pipeline itself and to the
coating. In case of localised points where the right-of-use is restricted to the minimum necessary
for the transit of mechanical equipment, the laying shall be carried out using other suitable
means. The pipe shall be placed on the floor of the excavation, without jerking, falling, impact or
other similar stresses. In particular, care must be taken that the deformation caused during the
raising of the pipe from the supports, does not exceed the values for the minimum allowable
radius of elastic curvature, so as to keep the stresses on the steel and on the coating within safe
limits. The portion of the pipeline between trench and bank shall be supported by as many sidebooms as required and approved by Company for holding the line in gentle S-curve maintaining
minimum elastic bend radius as specified in job standard. Lowering in and backfilling shall
preferably be carried out at the highest ambient temperature.
9.1.8 The pipeline must be laid without interruption for the whole or the length of section available.
Where water is present, no laying shall be permitted until the ditch has been drained to the extent
and for the time necessary to make visual inspection possible of the bed on which the pipe is to
be laid. Following such inspections, the presence of water will be permitted, provided that it is
not so high as to cause cave-in of the walls of the trench or floating of the pipeline before
backfilling, when weighing is not provided for the pipe.
9.1.9 Contractor shall take precautions immediately after lowering in to prevent the movement of the
pipe in trench.
9.1.10 Contractor shall close the two ends of the lowered section with night caps against ingress of
Water/mud or any foreign material in the section.
9.1.11 In laying parallel pipelines in the same trench, the minimum distances between the pipelines
indicated in the approved drawings shall be observed. Once the first pipeline has been
positioned, it shall in no way be disturbed by laying of the subsequent pipelines.
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At every seven meters along the trench sand/earth filled bags shall be placed between the parallel
pipelines so as to ensure maintenance of the minimum stipulated distance between the parallel
lines.
9.2
Overhead sections and sections in tunnel
9.2.1 The following works shall be completed before proceeding with the assembly and laying of
overhead pipelines:
-
Construction of the pipe support structures
Paints and/or coating of the pipe WORK, as indicated in the engineering specification.
9.2.2 The erection of the supports shall be carried out taking care that the elevation and alignment is in
accordance with the drawings.
In the case of metal work supports, pre-fabrication and/or assembly shall take into account the
maximum allowed free span and the supports shall not interfere with the pipeline welds.
9.2.3 In case roller supports are used, the rollers shall be lubricated, then checked for smooth rotation
and, in case of seizure, the defect shall be repaired or roller shall be replaced. In the case of
overhead section where the pipeline is slanting, the alignment of the end supports shall be made
after placing the pipeline in position. Before installation of the pipe section, all the rollers shall
be perfectly centered acting on the seat of the supports plates.
The above alignment operations shall be carried out before connecting the overhead section with
the end of the buried section.
9.2.4 Lifting, moving and laying of the pipeline shall be carried out in accordance with the provisions
of clause 9.1.5.
An insulation sheet shall be installed to isolate the pipe from the support or support from the
earth. The sheet shall be hard polyethylene at least 5mm thick. It shall extend at least to 1 cm
outside the saddles or clamps.
9.2.5 Moving supports, if any, shall be centered on their support and allow for a movement of at least
300mm in both directions.
9.2.6 A comprehensive report/method statement on the laying operation to be used shall be submitted
to the Company well in advance for approval. The report as a minimum shall include, but not
limited to the following:
a.
Method of installation by lifting (as a preferred method).
b.
Pulling method and related calculations, whenever lifting method cannot be used.
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c.
Pulling device and its characteristics including available pull force and FOS/margin
available w.r.t. calculated pulling load.
d.
Method of anchoring the pulling device
e.
Characteristics of the pulling rope
f.
Braking device, if any
g.
Pipeline assembly system.
10.0
BACK-FILLING
10.1
Backfilling shall not be done until the pipe and appurtenances have the proper fit and the pipe is
following the ditch profile at the required depth that will provide the required cover and has a
bed which is free of extraneous material and which allows the pipe to rest smoothly and evenly.
Before any such WORK is done, it shall be Contractor's responsibility to first secure the
approval of Company. If any backfilling is done without Company's approval, Company will
have the right to require removal of the backfill for examination, and the cost of such uncovering
and refilling shall be borne by Contractor. Backfilling of trench in water courses shall be carried
out as per the relevant specifications issued for the purpose.
10.2
Backfilling shall be carried out immediately after the pipeline has been laid in the trench,
inspected and approved by the Company, so as to provide a natural anchorage for the pipeline,
thus avoiding long exposure of coating to high temperature, damaging actions of adverse weather
conditions, sliding down of trench sides and pipe movement in the trench. If immediate back
filling is not possible, a covering of at least 200mm of earth, free of rock and hard lumps shall be
placed over and around the pipe and coating. On no account the top soil from the ROU be used
for this purpose. In general, the trench shall be dry during backfilling. Deviations thereof must
have prior approval of the Company. The backfill material shall contain no extraneous material
and/or hard lumps of soil, which could damage the pipe and/or coating or leave voids in the
backfield trench. After the initial backfill has been placed into the trench to a level slightly above
the surrounding ground, Contractor shall compact the backfill material. The surplus material
shall be neatly crowned directly over the trench and the adjacent excavated areas on both sides of
the trench as per clause 6.2.1, to such a height, which will, in Company's opinion, provide
adequately for future settlement of the trench backfill during the maintenance period and
thereafter. The crown shall be high enough to prevent the formation of a depression in the soil
when backfill has settled into its permanent position. Should depression occur after backfill,
Contractor shall be responsible for remedial WORK at no extra cost to Company. Surplus
material, including rock, left from this operation shall be disposed of to the satisfaction of land
owner or authority having jurisdiction at no extra cost to the Company.
For Further requirements reference shall be made to section 14.0 "Clean-up and Restoration of
Right-of-Use" of this specification.
10.3
Rock, gravel, lumps of hard, soil or like materials shall not be backfield directly onto the pipe
unless padding and/or rock-shield has been provided as per Section 6.8 of this specification.
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When "Padding" as described in Section 6.8 of this specification is to be used, the following
shall be applicable.
Where rock, gravel, lumps of hard soil or like materials are encountered at the time of trench
excavation, sufficient earth, sand or select backfill materials shall be placed around and over the
pipe to form a protective cushion extending at least to a compacted height of 150111m above the
top of the pipe. Select backfill materials for padding that are acceptable to Company shall be soil,
sand, clay or other material containing no gravel, rock or lumps of hard soil. Whether such
padding material would be taken from the adjacent spoil bank or imported from elsewhere shall
be directed by Company. All these works shall be carried out by Contractor at no extra cost to
Company. Loose rock may be returned to the trench after the required selected backfill material
has been placed, provided the rock placed in the ditch will not interfere with the use of the land
by landowner, or tenant.
10.4
When the trench has been dug through drive ways or roads, all backfills shall be executed with
sand or a suitable material as approved by Company and shall be thoroughly compacted. In
certain cases, special compaction methods, such as moistening or ramming of the backfill in
layers may be required by Company. Company and any public or private authority having
jurisdiction over a road, street or drive way may require that the surface of the backfill be
gravelled with crushed rock or some other purchased material and the road shall be repaved. In
such instances, Contractor shall comply with said requirements at no extra cost to Company.
10.5
Trenches excavated in dikes which are the property of railways or which are parts of main roads
shall be graded and backfiled in their original profile and condition. If necessary, new and/or
special backfill materials shall be supplied and worked-up. The materials required may include
gravel, special stabilization materials or stabilized mixtures. Moreover, special processing and/or
compacting methods shall require the approval of Company and/or competent authorities.
Stone-pitching/cement lining of Dyke walls, if dismantled during excavation shall be restored to
its original condition after backfilling and compaction to the entire satisfaction of Company and
concerned Authorities.
10.6
The trench in irrigated and paddy fields shall be backfield to within 300mm of the top, then
rammed and further backfield until the trench is completely backfield. Surplus material
remaining after the operation shall be spread over the RoU as specified in Section 14.0 "Cleanup
and Restoration of Right-of- Use", of this specification.
10.7
At the end of each day's WORK, backfilling shall not be more than 500 meters behind the head
end of lowered-in pipe, which has been padded and approved for backfill. The backfill shall be
maintained by Contractor against washouts and spreading etc., until the completion and final
acceptance of the WORK by Company.
10.8
Contractor shall furnish materials and install breakers in the trench in steep areas (slope generally
10% and more) for the purpose of preventing erosion of the back fill. The type of breakers
installed shall be as per the approved drawings. Breakers shall be constructed of grout bags filled
with a mixture of 4: 1 Sand : Portland cement at Company's direction. Contractor may propose
other methods such as foam dams etc. which shall be subject to approval by Company. Such
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works shall be at no extra cost to Company. Contractor shall pay attention to the direction of
backfilling in such steep areas.
10.9
When backfilling the trenches in sloping terrains or steep areas, where in the opinion of the
Company the backfill may be washed out of the trench, sheet piling or other effective water
breakers across the trench shall be provided by Contractor. This is to divert the flow of water
away from the trench into normal drainage followed before laying of the line. In no case, the
water is to be drained via the trench or via channels other than those followed before the line was
laid.
10.10 Contractor shall leave the pipe uncovered at certain locations to allow Company to survey the
top of the pipe and the level of the pipeline in the backfield trench. Within 48 hours after
backfilling, Company shall have carried out such survey and informed Contractor of any
realigning, if required. Thereafter Contractor shall compact the backfill.
The maximum allowable deviation from the centerline for land sections as staked out by
Company and as referenced by Contractor after backfilling is limited to following:
Pipeline dia upto and including 600 NB
200mm
Pipeline dia greater than 600 NB
300mm
10.11 Before backfilling of the trench, Contractor shall comply with the requirements of Clause 6.12 of
this specification.
10.12 Stabilization of backfill shall be carried out by the Contractor in sandy areas and other such
places, as directed by the Company. Contractor shall carry out the stabilization to have a
consolidated cover over the pipeline at no extra cost to Company.
The backfill shall be stabilized preferably with 150 mm layer of marl, mattresses of gatch other
than straw or other stable materials. The width of stablisation shall be at least 3.0 meters on
either side of the pipeline, plus one meter for every 10 meters height of dune (where the line
passes through the dune areas).
10.13 Temporary markers shall be installed during backfilling and the survey as per clause 10.10 to
locate the pipeline axis. These markers shall then be replaced with permanent pipeline markers.
10.14 Backfilling shall be preferably carried out at the highest ambient temperature.
10.15 In certain areas like U/G pipeline crossings, overhead power cable crossings etc, special care to
be taken by putting concrete slab/plastic grating before backfilling. Size and thickness of
concrete slab/plastic grating shall comply applicable job standard and approved by Company.
11.0
TIEING-IN
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11.1
The unconnected sections of the pipeline at various locations have to be tied in after the sections
are coated, lowered and backfield. The sections to be connected shall have at the ends, sections
of over lapping, uncovered pipe of sufficient length to absorb, without inducing excessive
stresses in the steel, small displacements necessary for perfect alignment and connection of the
ends.
11.2
Tie-in shall preferably be carried out at ambient temperatures corresponding to the average
operating temperature in the case of a pipeline conveying fluids at normal temperatures and at
the maximum ambient temperature in the case where the pipeline is carrying fluids at high
temperature.
11.3
Contractor shall carry out tie-in-welding (including necessary cutting, bevelling, grinding of pipe
weld seams and line-up etc.) cleaning, priming, coating and backfilling for the tie-in portion as
per relevant specifications. Contractor shall also excavate the required bell-holes for the welding.
Bell holes made to facilitate welding shall provide adequate clearance to enable the welders to
exercise normal welding ability and skill. All tie-in welds shall be radiographically examined.
11.4
The tie-in should be done in such a way as to leave a minimum of strain in the pipe. If necessary,
with respect to the trench, realigning of the pipe shall be done to eliminate force or strain in the
pipe by the Contractor at no extra cost to Company.
11.5
If a pup end cannot be avoided for tie-in, the minimum length that shall be added is 1.0 meter
and two or more such pups shall not be welded together. All cut-off lengths greater than 1.0
meter shall be moved ahead in order to be welded into the pipeline at a suitable location. Tie-in
with two or more pups may be used provided that they each have minimum length of 1.0 meter
and are separated by an entire length of pipe. In no case more than three (3) welds shall be
permitted on a 10 meter length of pipeline.
11.6
In connecting pipes, special items, fittings and equipment where different wall thicknesses are to
be welded, Contractor shall follow the procedures indicated in ASME B3 1 .WASME B3 1.4, as
applicable. The required tapering shall be done by Contractor at no extra cost to Company.
11.7
For tie-in of adjacent sections of pipeline already pressure tested, the pup used for tie-in shall be
of single length or off-cuts of pipe, which have already been hydrostatically tested. Contractor
shall take care that sufficient number of pretested pipes with different wall thicknesses are
readily available.
12.0
SPECIAL INSTALLATIONS ON THE PIPELINE
12.1
General
12.1.1 In addition to constructing the pipeline, Contractor shall also install certain other auxiliary
facilities and appurtenances.
Contractor shall do all WORK necessary at each of the installations to provide facilities, which
are complete in all respects and ready for operations.
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Without limiting the generality thereof, the WORK required to complete the installations shall,
where applicable, include all site surveys, site preparation, filling, grading, fencing, foundations,
installation of block valves, side valves, pipe work, pipe supports, pressure gauges, mechanical
facilities, civil work, painting, installation of all electrical equipments, motors, cables, conduit,
wiring and fixtures and hooking up of same; installation of all instruments, piping, valves and
fittings; mounting of all instruments and malting all piping and electronic connections, etc.
On completion, all elements of each entire installation shall be checked out and tested for full
and correct operation in the presence of, and to the satisfaction of Company. All WORK shall be
carried out strictly in accordance with the appropriate codes, the approved drawings, and this and
other related specifications.
Contractor shall fabricate all piping and install valves and fittings as required by the detailed
engineering fabrication drawings prepared by him and approved by Company. Piping fabrication
drawings shall be prepared by Contractor based on AFC drawings and approved by Engineer In
charge at site.
Stainless steel lines will he "swaged" using permanent fittings installed with a hydraulic device.
Cold bending for the fitting of 12 mm NB and 6 mm NB pipes is allowed when special bending
tools are used with guides to prevent flattening. The minimum radius allowed shall not be less
than R=10 D, where D = outside diameter of pipe.
The bending tools shall be subject to Company's approval.
Contractor shall ensure that the piping assemblies are not in a strain prior to the final bolting or
welding. Contractor shall also ensure that all equipment and piping are thoroughly swabbed
clean of all dust, refuse, welding-spatter, scale, or any potentially detachable matter prior to the
tie-in or final bolting.
12.1.2 Dimensional Tolerances
These tolerances apply to inline items and corrections for other lines. These tolerances can be
exceeded on items such as vents, drains, dummy supports, field supports, temperature and
pressure connections, where the deviation will not affect another spool.
a.
General dimensions such as face to face, face or end to end, face or end to centre, and
center to centre: + 3 mm.
b.
Inclination of flange face from true in any direction: 4mm per meter.
c.
Displacement of branch connection from indicated location: 1.6mm. When multiple

branches are involved, the displacement of the branches shall not exceed 3mm from a
common point.
d.
Rotation of flange bolt holes shall not exceed 1.6mm
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12.1.3 Flanged connections

Contractor shall ensure that prior to final bolting, all flange faces are parallel and centered,
according to standard practice. Contractor shall not use bolting forces as a means for attaining
alignment. A gasket of required size and quality shall be installed between the flanges at each
joint.
Bolts shall be tightened in diagonal sequence and shall be centered with equal amounts of thread
visible on both sides. Bolts shall be uniformly tightened to produce a leak-proof joint. Bolts that
yield during tightening shall be removed and discarded. It is mandatory that a torque wrench is
used for bolt tightening.
12.1.4 Threaded connections
Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.
Contractor shall properly align all threaded joints. Pipe entering unions shall be true to centerline
so the union will not be forced during make-up. The threaded pipe shall not project through
fittings to cause interference with valves or other operating mechanisms.
Except for the threaded connections of instruments, which will require periodic testing and
maintenance, all threaded joints shall be seal welded. The latter joints shall be made up without
pipe joint compound and with a minimum of oil from the thread cutter. Seal welds should taper
into the pipe with as little discontinuity as possible, and should cover all threads. All seal welds
shall be tested with DP, MP testing.
12.1.5 Welded connections
Where the ends of the piping components being welded have an internal surface misalignment
exceeding 1.6mn-1, the wall of the component extending internally shall be trimmed by
machining so that the adjoining internal surfaces will be approximately flush. All welding shall
be performed in accordance with GAIL Specification of Welding Specification for Onshore
pipeline for Transportation of Gas and other applicable Jobs Specifications and Welding
Specification Chart.
Tie-ins between fixed points shall be made at maximum ambient temperature.
12.1.6 Civil Work
Civil work shall be performed in accordance with Specifications issued for the purpose.
12.1.7 Painting
All exposed surfaces like piping, valves, structures, and miscellaneous appurtenances shall be
painted in accordance with the specifications issued for this purpose. The corrosion coating on
pipe surface will end approximately 300 mm above the finish grade and it will be necessary for
Contractor to provide a clean interface at the junction of the protective coating and the paint.
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12.1.8 Coating of buried Installations, etc.

All buried valves, insulating joints, flow tees, bends, other in-line fittings and appurtenances
shall be coated with 100 % solid high build epoxy (minimum 500 micron thk.) or any other
equivalent suitable Company approved coating at no extra cost to Company. For buried pipes
and LR bends, heat shrink sleeves / cold applied tapes conforming to Company's specification
for Field Joint Coating shall be used. Contractor shall submit to Company a report regarding the
method of application and the materials used along with all test certificates. Only after obtaining
written approval from the Company, Contractor shall commence the work of coating.
12.1.9 Clean-up
After all required tests have been concluded satisfactorily, Contractor shall clean up the Site as
laid down in the specifications issued for the purpose. The Site shall be graded in accordance
with the approved drawings.
12.2
Installation of valves and valve stations
12.2.1 Block and sectionalizing valve stations shall be installed as shown on the approved drawings. It
is Contractor's responsibility to have the units completely assembled, tested and made fully
functional including all related instruments etc.
12.2.2 The civil and structural work shall be carried out in accordance with the relevant specifications
issued for the purpose and in accordance with the approved drawings as directed by Company.
This work as a minimum shall include clearing, grading, fencing, foundations etc. as required.
All above ground structures shall be painted as per the specification and color code given by the
Company.
12.2.3 Suitable concrete foundation as directed by Company shall be constructed on which the valve
shall be firmly installed, after embedding an insulating sheet of hard polyethylene with a
thickness of at least 5min or equivalent. Such insulating sheet is also to be installed under pipe
clamps, etc.
12.2.4 Valves with flow arrows shall be installed according to the normal flow in the pipeline. During
welding, the valves shall be in fully open position. In addition, all manufacturer's instructions
shall be followed.
Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.
12.2.5 For valves and piping installed below ground and/or above ground the anti-corrosion
Coating/painting shall be as per the requirements of the relevant specifications issued for the
purpose. The anti-corrosion below ground coating shall extend upto 300mm above grade at the
lowest point.
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12.2.6 Sectionalising valves shall be installed on sections of the pipeline in the horizontal position only
or with an inclination not greater than that allowed by the valve manufacturer. Installation shall
be done in such a way that there is no strain in the welded joint while the pipeline at upstream
and downstream side are straight.
12.2.7 All valves shall always be handled using appropriate equipment and methods so as to avoid
impact, shaking and other stresses. In particular, the equipment and tools used for lifting and
handling shall never be hooked through hand wheel, valve stem, flange joints and other parts,
which may suffer damage/misalignment.
12.2.8 All sectionalising valve and any other inline assemblies shall be prefabricated and tested
hydrostatically ex-situ as per applicable specification. All such assemblies shall be installed at
the locations shown in the drawings only after successful completion of the hydrostatic test and
dewatering. Thereafter the ends of the assembly shall be closed off, Contractor shall carry out
necessary excavation, cutting, beveling of pipe ends and welding of the tie-ins required for the
installation of such assembly. The tie-in joints shall be radiographically examined over 100%
length and also 100% ultrasonically examined prior to backfilling. All works shall be executed in
accordance with the relevant specifications issued for the purpose.
12.3
Installation of scraper launchers and receivers
12.3.1 Scraper stations shall be fabricated and installed as per the approved drawings and whenever
applicable as per the requirements of clause 12.2 of this specification. It is Contractor's
responsibility to have the units completely assembled tested and made fully functional including
all instruments and related piping.
12.3.2 The Civil and structural works for the scraper stations shall be carried out as per the relevant
specifications, in accordance with the drawings and as directed by the Company. The WORK as
a minimum shall include site survey, site preparation, clearing, grading, fencing, foundations,
etc. as required.
12.3.3 It shall be Contractor's responsibility to maintain elevations shown on the approved drawings and
to carry out any pipe work adjustments, necessary for this purpose. Field cuts shall be square and
accurate and field welds shall not be performed under stress of pipe ends.
12.3.4 The painting for the scraper stations shall be carried out as per "Specifications for Painting". The
underground sections shall be coated as specified for the pipeline upto at least 300mm above
grade.
12.3.5 The hydrostatic testing of the scraper stations shall be executed after installation in accordance
with the relevant specifications issued for the purpose.
12.4
Installation of insulating joints
12.4.1 Insulating joints shall be installed at the locations shown in the drawings. Contractor shall obtain
approval from the Company before installation of the insulating joints.
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12.4.2 Handling and installation of the insulating joints shall be carried out with all precautions required
to avoid damage and excessive stresses and that the original pup length is not reduced.
12.4.3 The insulating joints and the welded joints shall be protected by external coating as per relevant
specifications issued for the purpose.
12.4.4 When the in-line inserting is made on the buried pipeline, care shall be taken to weld at an
external temperature as close as possible to the pipeline operating temperature.
The joint shall be inserted on straight sections and laid on a fine sand bed.
12.4.5 During the execution of the in-line connection welding, the propagation of heat shall be avoided.
To achieve this, the joint shall be kept cold by means of rags continuously wetted.
12.4.6 Insulating joints shall be e1ectrically tested before welding into the pipeline. The electrical
resistance/conductance test shall be carried out using a Megger. Measurement of the insulation
resistance across the joint shall be approx. one (1) Mega Ohm. The tests shall be repeated after
installation and welding of the joint into the pipeline to verify that the assembly is undamaged.
13.0
WORKING SPREAD LIMITATIONS

Contractor shall, in general, observe the following maximum distances between the working
mainline spread:
Between ROU grading, clearing and backfilling
25 Kms
Between backfilling and final clean-up
05 Kms
The spread limitations do not apply to point spreads such as rock blasting, river crossing and
bored crossings of roads, railways and canals and HDD crossings.
Any deviations from the above shall meet prior approval of Company. Company reserves the
right to stop the WORK, in case the approved spread limitations are exceeded and Contractor
shall not be paid any compensation for stoppage of WORK.
14.0
CLEAN-UP AND RESTORATION OF RIGHT OF USE
14.1
Contractor shall restore the RoU and all sites used for the construction of pipelines, water
crossings and other structures in accordance with Company's instructions, and deliver them to
the satisfaction of Company.
14.2
Surplus materials
For Company supplied materials, after completion of WORK, the Contractor shall return all
surplus materials at Company's designated areas.
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The reconciliation of surplus free issue line pipes shall be as per the requirement of commercial
condition of contract.
14.3
Disposal
14.3.1 All surplus and defective materials supplied by Contractor and all trash, refuse and spoiled
materials shall be collected and disposed off by Contractor.
14.3.2 The ROU shall be cleared of all rubbish, broken skids, empty cans, card board, sacks, stumps,
trash, and leftover construction material. All burnable matter shall be burned, but only after
obtaining appropriate permits for such burning. If burning is not allowed, Contractor shall haul
the clean-up material to an approved dumping area. All scrap metal and unburnable material
shall be disposed of, in an appropriate manner, but never be buried in the ROU.
14.3.3 Surplus soil can only be removed from the Owner's plot after authorisation by Company.
14.3.4 All dumping fees connected with the disposal of materials shall be to the account of Contractor.
14.3.5 All loose stones and rock exposed by the construction operations and scattered over the ROU or
adjacent grounds shall be removed by Contractor and be transported to a location considered
suitable by the land-owner and/or tenant, or by authorities have jurisdiction, for satisfactory
disposal. For stones, gravel or other hard material, which may be buried in the trench the
provisions of the specifications shall apply with the understanding that the use of the land by the
land-owner and/or tenant will not be interfered with.
14.4
Temporary structures
All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which were
erected or installed by Contractor as temporary measure, shall be removed. However, it may be
necessary to remove the fence of ROU during the maintenance period.
14.5
Repair of damages
Damages to roads, bridges, and private property shall be repaired by Contractor. All fences and
other structures, which are damaged during construction, shall be restored to original.
Slopes, water course sides or banks which have been partially or totally demolished during the
execution of the works shall be properly consolidated and restored (without waiting for their natural consolidation and settling) complying to requirement of the concerned Authorities. The
bed of water-courses shall be restored to the original level. The banks and any excavated areas
shall be restored to the original levels and contours. The banks shall also be stabilized.
All boundary stones, which have been moved or removed during the WORK must be reset in
their original location to the satisfaction of the landowner concerned.
14.6
On completion of clean-up, the ROU shall be restored to such stable and usable condition as may
be reasonably consistent with the condition of the RoU prior to laying the pipeline. The
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Company shall be completely indemnified and held harmless by Contractor from any and against
all claims, demands, losses, expenses etc. that may arise in this behalf or the Company may
anyway suffer or sustain, relative to, arising out of, or in connection with same. The Company
may require from the Contractor signed Releases from landowners regarding satisfactory
indemnification and restoration of their lands.
14.7
Special precautions shall be taken near steep slopes prone to erosions and landslides. All
necessary steps shall be taken to ensure the rapid growth of grass by providing wicker barriers
and by regulating the drainage of surface waters.
14.8
All cadastral or geodetic markers, which may have been removed during the execution of the
WORKS, shall be restored in their exact position.
14.9
Ditches for which no instructions for their restoration have been issued, or restoration cannot be
done due to absence of banks, shall be restored as instructed by Company. The bed of ditches
crossed by the pipeline shall be cleaned over the full width of the ROU, also outside the ROU if
necessary. This restoration might contain but is not limited to the supply and installation of
proper materials for backfill and protection, the sodding or other precautions to prevent erosion
or guarantee the stability. All work has to be done after deliberation and acceptance of the
authorities and Company. Other field drains have to be restored over full width of ROU and if
necessary also outside the ROU by hand and/or special equipment as soon as possible.
14.10 Any subsidence, cave-ins, wash-outs, which have been caused during the pipeline construction
and maintenance, caused by whatever reason within the edge of ditches and open drains, shall be
repaired by Contractor immediately or at first notice given by Company.
14.11 After the clean-up, the ROU of pastures has to remain fenced considered suitable by the tenant
and to be removed during the maintenance period. When agricultural and other traffic (requested
by tenant) have to cross the ROU the cross-overs have to be fenced with the same material as the
ROU. If necessary, special materials have to be used to allow traffic on the cross-over. Fencing
of the right-of-use as specified shall not be removed until Contractor has obtained written
permission by Company. In general this has to be done during the maintenance period.
14.12 All openings in or damage to the fences or enclosures shall be repaired by installing new fencing
of a quality, which shall be at least equal to the parts damaged or removed. Provisional gates
shall be removed and replaced with new fencing. All repairs to fences and enclosures shall be
carried out by Contractor to the complete satisfaction of Company, landowner and/or tenant.
14.13 If, in the opinion of Company, the sod in pasture land has been damaged by vehicles and wheel
tracks are visible, the ROU shall be tilled with a disc-harrow or rotary cultivator several times.
The damaged sod shall be firmly cut up and thoroughly mixed through the top-soil. In general,
the ROU has also to be ripped. After this procedure no closed-in layers must be found and
sufficiently loose top-soil 25 to 30 cm thick must be present. The whole procedure must be
approved by Company. Subsequently, the entire ROU, which is part of pasture land, shall be
prepared for seeding and fertilized by Contractor according to the instructions of Company.
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14.14 In crop fields the tillage shall consist of passing over the land several times with a disc harrow,
cultivating with a spading machine, or plow, to a depth of approx. 20 cm. In general the ROU
has also to be ripped. After this cultivation process no closed-in layers must be found any more
in the ROU. The equipment used and methods adopted shall require the approval of Company.
Ripping has to be done with rippers with a distance of 50 cm between the ripper blades. The type
to be used shall be approved by Company.
14.15 Adequate numbers of saplings of any plant/tree uprooted or cut during construction shall be
planted along the route as per the direction of the Company and in accordance with the
requirement of Authorities. The cost of sapling and its plantation shall be to Contractor's
account.
14.16 The ROU and the backfilled trench in particular has to be finished in such a way that after
settlement of the soil the fields are at their original level.
If during the maintenance period certain parts of the ROU are lower than the original level,
Company can order Contractor to bring these parts to the original level.
In cases where heavy damage has occurred to the structure of the subsoil as a result of adverse
circumstances, Company reserves the right to order Contractor to carry out special restoration
work. Said special work can include:
-
Spading with dragline (depth 30-80 cm);
Spading with dragline (depth 80-100 cm);
fertilizing;
cover with sand.
If during clean-up operations soil shortages become apparent outside the trench, Contractor shall
supplement said soil shortage using suitable materials, approved by Company.
If site and/or climatic conditions should render this necessary, Company shall have the right to
order Contractor to suspend certain parts of the work related to the clean-up and postpone it to a
later date.
14.17 Soil surplus
If on site, as a result of the WORK and after careful backfilling and compacting, a sub-soil
surplus exists, this shall be worked up by grading and compacting below the sub-soil top layer
and as a rule this shall be done in the same plot of land. It shall not be permitted to remove the
surplus from the plot concerned, unless it concerns rejected soil, which has to be removed.
Working up surplus soil or removal of rejected soil shall be considered to pertain to the WORK.
To work a soil surplus into the ground, Contractor shall remove an additional strip of top soil
beside the trench. Next, the upper layer of sub-soil shall also be removed. Both soil types shall be
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stored separately across a width depending on the size of the soil surplus. The soil surplus shall
then be distributed across the trench thus widened, after which it shall be graded and compacted
and subsequently the top layer of sub-soil and the top-soil shall be replaced in the correct order,
in accordance with the Specifications.
In case Company has given prior permission for mixed excavation of the sub-soil as well as in
cases where Company deems mixed excavation permissible, the above provision of separate
storage of the upper layer of sub- soil shall not apply to the working up to the soil surplus.
In cases where the soil surplus can be worked up in others plots where soil shortages have arisen
due to the WORK, this shall only be done after prior permission by land-owner, land-user and
Company.
14.18 Soil shortages
If due to unforeseen circumstances during backfilling and compacting there should not be
enough soil to fill the trench properly, or to install the crown height as stipulated, Contractor
shall supply the necessary backfill material.
Soil shortages shall be supplemented and applied before the top-soil is replaced.
The soil to be supplied shall be worked up in those locations and into those layers where a soil
shortage has been established. The quality of the supplemented soil shall be equal to that of the
shortage.
15.0
MAINTENANCE DURING DEFECTS LIABILITY PERIOD

Defects Liability Period (defined as period of liability in the CONTRACT) means the period
calculated from the date certified in the Completion Certificate.
Company reserves the right to carry out instrumented pigging survey of the completed pipeline.
Contractor shall be responsible for making good with all possible speed at his expense any defect
in or damage to any portion of the Work which may appear or occur during the Defects Liability
Period and which arises either:
a.
From any defective material (other than supplied by Company), Workmanship or design
(other than a design made, furnished or specified by Company and for which Contractor
has disclaimed responsibility in writing), or
b.
from any act or omission of Contractor done or omitted during the said period.
If such defect shall appear or damage occur, Company shall forthwith inform Contractor thereof
stating in writing the nature of the defect or damage.
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If any such defect or damage be not remedied within a reasonable time, Company may proceed
to execute the WORK at Contractor's risk and expense provided that he does so in a reasonable
manner. Such defect or damage can be, but is not limited to:
-
Clean-up of ROU, including water courses
Sagging or sinking of site level or pipe supports
Sliding of ditch banks
Repair of fencing or removal of construction fencing
Repaving of pavements, repair of pavements, repair of Roads
Repair of coating, painting
Realigning markers, signs
Leak/burst of pipe, leaking of flanges, washouts
Short-circuit in casings
Construction defects such as dents, ovality, welding offsets/defects, etc. detected during
intelligent pigging survey, etc.
Company reserves the right to have the required Computerised Potential Logging Test executed
during the DEFECTS LIABILITY PERIOD and whenever weather conditions are more
favorable for this job. The work shall (at or as soon as practicable after the expiration of the
Defects Liability Period) be delivered to Company in the conditions required by the
CONTRACT, fair wear and tear excepted, to the satisfaction of Company. Contractor shall finish
the work, if any outstanding, at the date of completion as soon as possible after such date and
shall execute all such work.
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FOR
HYDROSTATIC TESTING OF ONSHORE
PIPELINE
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Abbreviations:
ASME
API
OISD
Oil Industry Safety Directorate
SMYS
Specified Minimum Yield Strength
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1.0
SCOPE
1.1
This specification covers the minimum requirements of supply, work and operation to be
performed by Contractor for hydrostatic testing of cross-country steel pipelines transporting
hydrocarbons in liquid or gaseous phase under high pressure.
This specification does not cover the requirements of caliper pigging, drying/ pre-commissioning
of the tested pipelines.
1.2
.
2.0
2.1
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.

Reference has been made in this specification to the latest edition (edition enforce at the time of
floating the enquiry) of the following codes, standards and specifications.
a)
ASME B 31.4

and Other Liquids
b)
ASMEB 31.8
Gas Transmission and Distribution Piping systems.
c)
API RP 1110
Pressure Testing of Liquid Petroleum Pipelines.
d)
ASME Sec. VIII Div. 1 -
Boiler and Pressure Vessels Code.
e)
OISDB141
Design and construction requirements for cross-country

f)
(i)
ii)
Welding Specification for Onshore Pipelines for Transportation of Gas.
2.2
In case of conflict between the requirements of above mentioned codes, standards, specifications,
practices, the most stringent requirement shall govern.
2.3
-
The words "Shall" and "Must" are mandatory.
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the words "Should', "May" and "Will" are non-mandatory, advisory or

recommended.
3.0
GENERAL
3.1
Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall be
performed in accordance with approved Hydrostatic Test Diagrams clearly indicating the number
of test sections and minimum and maximum test pressures in each test sections. The maximum
length of each test section shall not exceed 50 Kms.
3.2
For pipeline sections which in Company's opinion, once installed would require an inordinate
amount of effort for repair in case of a leak, a provisional pre-test shall be conducted. However,
after installation, such pre-tested sections shall be tested again along with the entire pipeline.
3.3
Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all welds
have been accepted and the pipeline has been laid and backfilled. Hydrostatic test shall include
those sections which have been previously tested viz. Rail/ road crossings, major water crossings
including test on banks and in place after installation, and scraper traps at the terminals.
Contractor shall perform all works required for hydrostatic testing after obtaining prior written
approval from the Company.
4.0 HYDROSTATIC TEST PROCEDURE MANUAL

Contractor shall prepare for Company's approval a hydrostatic test procedure manual. The
procedure shall strictly comply with the requirements of this specification and shall be submitted
to Company for approval well in advance. The procedure manual shall include all temporary
materials and equipment, but not be limited to the following items:
a)
A diagram for the system to be tested, indicating all fittings, vents, valves, temporary
connection, relevant elevations and ratings. The diagram shall also indicate injection
locations and intake and discharge lines.
b)
Estimated amount of test water, water source, including required concentration of

corrosion inhibitors and additives, procedure for inhibitor injection and control of
concentration.
C)
Filling and flushing procedures, including a complete description of all proposed

equipment and instruments (including spares), their location and set-up.
d)
The type and number of pigs to be used, gauging plate parameters, sequence of pigs to be
launched during pig tracking system for cleaning and removal of air pockets. Pig
inspection procedures, including procedure to be followed in case the caliper pig
indicates damage to pipeline in access of the values specified in governing codes.
e)
Procedure for levelling and stabilization after filling and for pressurization and to allow
for temperature stabilization.
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f)
Pressure testing procedure including a complete description of all proposed equipment

and instruments (including spares), their location and set-up and proposed system for
observation and recording of data during the pressure test.
g)
Procedure for detection and location of leaks.
h)
Procedure for dewatering the pipeline sections(s) after testing, including a complete
description of all proposed equipment and instruments (including spares), their location
and set-up, the type and sequence of pigs and the pig tracking system along with the pig
specification.
i)
Forms for recording the test data.
5.0
TEST DURATION AND PRESSURE
5.1
The duration of hydrostatic test shall be minimum 24 hours after thermal stabilization.
5.2
Unless specified otherwise in the Contract, the hydrostatic test pressure shall be as follows:
For pipeline handling hvdrocarbon in gaseous phase:
a)
1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 3 1.8.
b)
1.4 times the design pressure for pipeline located in Class-3 and Class-4 locations as per
ASME B 31.8.
For pipeline handling hydrocarbon in liquid phase:

a)
1.25 times the design pressure for pipeline handling liquids including Liquefied
Petroleum Gas (LPG).
The test pressure, as calculated above, shall be generated at the highest point in the section under
test. At any point in the test section hoop-stress due to test pressure and static head shall not
exceed 95% of the SMYS of pipe material.
6.0
EQUIPMENT AND INSTRUMENTATION

The Contractor shall furnish all necessary equipment for performing the work as stated in
cleaning, flushing, filling, stabilising, testing and dewatering procedures.
This shall include, but not be limited to the following equipment and instruments:
a)
Pigs for cleaning, filling and gauging
Cleaning pigs with spring loaded steel wire brushes. For internally coated pipes, the pigs
shall be provided with nylon/ polyurethane brushes.
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Four cup batching pigs.
Gauging pigs fitted with gauge plate.
The Contractor shall provide a sufficient number of pigs, including spares.

b)
Fill pumps:
The Contractor shall determine the type and number of fill pumps in order to guarantee the
following:
-
differential head 20% greater than the maximum required
Flow rate : Minimum 400 m3/h; Maximum 1000 m3/ h
If a single pump is used, a standby unit must be available.

c)
Variable speed positive displacement pumps equipped with a stroke counter to pressurize the
pipeline. The pump shall be capable of exceeding the maximum test pressure by at least 20 bar.
d)
Two positive displacement meters to measure the volume of water used for filling the line. These
meters shall be provided with a calibration certificate not older than one month.
e)
Portable tanks of sufficient size to provide a continuous supply of water to the pump during
filling and pressurizing.
f)
Bourdon pressure gauges of suitable pressure range and accuracy.
g)
Dead weight testers with an accuracy of 0.01 bar measuring in increment of 0.05 bar provided
with a calibration certificate not older than one month at the time of the first hydrostatic test in
the pipeline.
h)
Two 48 hours recording pressure gauges complete with pressure recording charts and ink, duly
tested with dead weight tester prior to use. These shall be installed at the test head.
i)
Pressure recording charts.
j)
Two temperature recorders for fill water.
k)
Thermocouples duly calibrated for measuring the pipe wall temperature.
l)
Two laboratory thermometers of range 00C to 600C and with accuracy of 0.10C to be used in
thermowells.
m)
Means to measure the volume of water necessary to drop the line pressure by 0.5 bar (container
on scales or graduated cylinder)
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n)
Injection facilities to inject additives into the test medium in the required proportions.
o)
Communication equipment suitable for a continuous connection between the beginning and the
end of the test section and with the inspection team along the line, in accordance with the
requirements of Local Authorities.
p)
The temporary scraper traps shall be installed according to the test section fixed in the test
procedure manual. Proper piping and valving arrangements shall be available to allow lunching
and receiving of each pig independently.
The test heads shall be sized in conformity with ASME specification Section VIII, Division 2
with particular reference to Appendices 4 and 5.
q)
Thermocouples for measuring the temperature of the pipe wall shall be installed on the pipeline
to be tested:
-
One (1) thermocouple at about 500 m distance from the pumping head.
One (1) thermocouple every 2500 m of the pipe. The spacing may be increased to
maximum 5000 m depending on the terrain and nature of sub soil along the alignment of
test section.
One (1) thermocouple at about 500 m distance from the terminal head.
Thermocouples shall be attached on the external surface of the pipe after removal of external
coating and shall be adequately protected and Company's coating instructions shall be followed.
After successful testing, the thermocouples shall be removed and damaged coating shall be
repaired as per applicable coating repair procedure, approved by Company.
7.0
PROCEDURES
7.1
Equipment andlor parts which need not or must not be subjected to the test pressures or which
must not be tested with water, must be disconnected or separated from the pipeline to be tested.
7.2
If the difference of minimum and maximum atmospheric temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps and
above ground pipeline shall be properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz.
aerial lengths on piers, suspension bridges, etc. Such sections shall be tested separately.
7.3
The test medium shall be soft non-aggressive water furnished by the Contractor. The water to be
used shall be filtered, shall not be contaminated and free from sand of silt. Contractor shall
submit laboratory test reports of water used for testing. The possible use of sea water shall be
subjected to its degree of cleanness, the possibility of obtaining a pre-determined salinity
neutralisation and the use of corrosion inhibitors, this at the sole discretion of Company.
Contractor shall provide Company approved corrosion inhibitors, oxygen scavengers and
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bactericides to be added to the test water. The Contractor shall furnish and install all temporary
piping, which may be necessary to connect from source of water to its pump and manifolds/
tankages.
The following products are acceptable for corrosion inhibition of the water used for hydro
testing:
-
REMIDOL 4000 of M/s Chemtreat India Ltd., Navi Mumbai.
HIBITOL 2000 of M/s Renkal Chemical, Navi Mumbai.
INDION 175 of M/s Ion Exchange India Ltd., Hyderabad.
VISCO 3900 of MIS NALCO EXXON.
Dosage for inhibitor shall be as follows:

-
Upto 6 months 500 mg/l

Above 6 months 750 mg/l
Contractor shall note the following:

a.
All chemicals for hydrotesting shall be procured from approved vendors. Chemicals older than
three months shall not be used.
b.
Company representative shall inspect the chemical containers and take random samples prior to
its use. Contractor shall get the samples tested in an GAIL nominated Govt./PSU/other
competent laboratories. Testing shall be carried out for accelerated % corrosion inhibition
efficiency, % SRB and TBC killing efficiency test. Company reserves the right to witness the
testing. The test report shall be submitted to Company for approval prior to undertaking hydro
testing works.
c.
Only those chemicals which have passed the above tests shall be used for hydrotesting.
7.4
Before filling operation, the Contractor shall clean the pipeline by air driven pigs provided with
spring loaded brushes and chisels to remove all mill scale, rust, sand, etc. from the internal of
pipe section. For this purpose, temporary headers for air cleaning shall be attached to the
pipeline. The number of pig runs is depending upon the cleaning results and shall be determined
by the Company at site.
7.5
After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried out
by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter of the
heaviest all pipe in the test section. While computing the ID of heaviest wall pipe, pipe
manufacturing tolerances shall not be considered. A 10 mm thick aluminium plate shall be used
for making gauge plate.
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After receipt of gauging pig at the other end, the gauge plate shall be inspected in the presence of
Company representative. A deformed, bent or severally nicked plate or damaged pig shall be
evidence of gauging pig run failure and the same shall not be acceptable to COMPANY. In such
cases the Contractor shall repair and rectify the line and repeat the gauging pig run to the
satisfaction and approval of the Company Representative. Any obstruction and/ or faults such as
dents, buckles, flat spots, etc. analysed and noted during gauging pig run shall be located and any
necessary repair work shall be performed to rectify the same to the satisfaction of the Company.
A written approval shall be obtained from Company regarding successful completion of gauging
pig run.
After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pig shall be welded to test section.
Joints between test header and pipeline shall be radiographed. Un-inhibited water equal to 10%
of the volume of test section shall be introduced in front of the first pig. The first pig shall be
launched by introducing about 1.5 km un-inhibited water. Then the second pig shall be launched
by pumping the inhibited water till the second pig is received at the other end. Subsequent to
receipt of second pig, the pressurization and thermal stabilization operation can commence.
7.6
Thermal stabilization
After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, the thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked through the
Thermocouples installed on the pipeline.
Temperature readings shall be made at 2 hours-intervals. Thermal stabilization shall be
considered to have been achieved when a difference not higher than 1C is attained between the
average values of the last two readings. Thermal stabilization completion shall be approved by
Company.
7.7
Pressurisation
7.7.1 The pressurization shall be performed in the presence of Company at a moderate and constant
rate not exceeding 2 bars/ min. One pressure recording gauge shall be installed in parallel with
the dead weight tester. Volume required to reach the test pressure shall be recorded periodically
throughout the pressurization as follows:
a)
b)
C)
each 5 bar increments up to 80% of test pressure as recorded by the dead weight tester;
each 2 bar increments between 80% to 90% of test pressure as recorded by the dead
weight tester;
each 0.5 bar increments between 90% of the test pressure to full test pressure as recorded
by the dead weight tester.
7.7.2 The pressurisation shall be cycled according to the following sequence:
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a)
b)
C)
d)
e)
Pressurise to 50% of test pressure, hold pressure for 1 hour,

Drop pressure to static head of test section at test head,
Pressurise to 75% of test pressure, hold pressure for 1 hour
Drop pressure to static head of test section at the test head
Pressurise to test pressure.
During the pressurisation to each test pressure, two tests shall be carried out for the calculation of
air volume in the pipeline under test.
In case, during the hold pressure periods indicated above, a decrease in pressure in observed, the
above operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the Contractor has isolated and eliminated the cause for the lack
of water tightness.
7.9
Air Volume Calculation.

In order to check the presence of air in the pipeline, two separate consecutive pressure lowering
of 0.5 bar shall be carried out after pressurizing to test pressure.
For calculation of air in the pipeline the second pressure lowering shall be used, and the relevant
drained water shall be accurately measured (V1). This amount measured shall be compared to
the theoretical amount (Vp) corresponding to the pressure lowering that has been carried out, by
using the procedure outlined in clause 12.1 of this specification.
If no air is present in the length under test:
In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.1.06). If
the air found in the pipeline is within the above established tolerance, then the pressurising can
continue. If the ratio VINP exceeds 1.06, the hydrostatic testing cannot go on and additional pig
passages shall be performed to remove the air pockets.
The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurising can then continue, to reach the value of the test pressure.
7.10
Testing
After the section has been pressurised and the air volume test has given acceptable results the test
pressure shall be held for a minimum of 24 hours after stabilisation. After temperature and
pressure has stabilished, the injection pump shall be disconnected and all connections at the test
heads shall be checked for leakage. The pressure recorders shall then be started with the charts in
a real time orientation for continuous recording throughout the test.
During the testing period the following measurements shall be recorded/ reported
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every one hour pressure measurements from dead weight testers.
every two hour the ambient temperature and the pipe temperature at the thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded. Bleed-off water
shall be accurately measured and recorded.
8.0
ACCEPTANCE
8.1
The hydrostatic test shall be considered as positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such changes shall be
evaluated as described under clause 12.2 of this specification.
The pressure change value as a function of temperature change shall be algebraically added to
the pressure value as read on the meters. The pressure value thus adjusted shall be compared
with the initial value and the test shall be considered as acceptable if the difference is less than or
equal to 0.3 bar. Incase of doubt the testing period shall be extended by 24 hours.
8.2
If test section fails to maintain the specified test pressure after isolation, Contractor shall
determine the location of leakage or failure by suitable means. All leaks and failures within the
pipe wall or weld seams shall be repaired by replacement of entire joint or joints in which
leakage or failure occurs. In those cases where leaks occur in circumferential welds the method
of repair shall be determined by the Company. Contractor shall comply with instructions of the
Company whether to replace a section of the line pipe that includes the line leak or whether to
repair the circumferential weld. This repair should, however, meet the requirements of applicable
welding specification enclosed with the Contract. Where failures occur in pipeline field bends,
bends shall be replaced with same degree of bends. After completion of repairs, the hydrostatic
test shall be repeated in full, as per this specification.
8.3
The cost of repairs or replacements, followed by refilling and repressurising the line, due to poor
workmanship, shall be borne by the Contractor. In the event of leaks or failures resulting from
faulty Company furnished materials, Contractor shall be reimbursed as per the provisions of
Contract. All work of reinstalling line pipe, to replace failures, shall be done in accordance with
the relevant specifications included in the CONTRACT.
8.4
Contractor shall haul and stockpile all damaged and defective pipes to storage location
designated by the Company. All cracks and splits resulting from failure shall be coated with an
application of grease to preserve the characteristics of failures from corrosion. Joint of failed
pipes shall be marked with paint, with a tag indicating failure details, date and location of failure
and pressure at which failure occurred.
9.0
TERMINATION
After the positive result of testing and all the data have been gathered, the test shall be terminated
upon written approval given by the Company. The pipeline shall be slowly depressurised at a
moderate and constant rate as instructed by Company. Subsequent operations such as caliper
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pigging, swabbing, drying, purginghnertising and commissioning shall be carried out as per the
applicable specifications enclosed with the Contract.
9.1
Contractor shall dewater the tested line as per the following requirement after test acceptance.
The dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed
air. The detailed dewatering procedure shall be deployed by the Contractor in such a way as to
provide adequate control of pigs during dewatering. Pigs and equipment required for dewatering
the line shall be furnished by Contractor and shall be approved in advance by the Company. Four
cup pigs shall first be passed through the line to displace the water. Foam pigs shall then be
passed in order to complete the line dewatering. Contractor shall use a number of foam pigs each
in different colours/numbered for this purpose. The line shall be considered dewatered when a
negligible amount of water is flushed out by the last foam pig and approval is given by the
Company.
9.2
During dewatering, care shall be taken to properly dispose the discharging water in order to
avoid pollution, damages to fields under cultivation and/ or existing structures and interference
with the traffic. Before the start of dewatering and disposal of hydrotest water, a procedure for
treatment of inhibited water to prevent pollution shall be submitted by Contractor to Company
for review and approval.
9.3
Upon completion of the testing and dewatering operation, any provisional traps for pigs and all
other temporary installation relating to the test shall be removed. Subsequently, the individual
sections of the line already tested shall be joined in accordance with the requirements of relevant
specifications issued for the purpose.
10.0
TEST REPORT
A complete report signed by Contractor and the Company shall be submitted upon completion of the
hydrostatic test for each test section.
This report shall contain as a minimum:
- the cleaning, flushing, filling and testing procedures used;
- schematic layout of cleaning, filling and testing facilities;
- instruments calibration certificate;
- a profile of the pipeline that shows the test sites, all instrument and injection connections;
- pipe filling logs and records;
- additive specification, required concentration and additive injection records;
- pig specifications;
- pig inspection records including photographs of the damages;
- records of gauging pig survey and photographs;
- pressurisation and stabilisation records;
- pressure and temperature recording charts with appropriate information inscribed thereon;
- temperature data along the pipeline;
- dead weight tester logs and recordings;
- air volume calculations;
- pressure change due to temperature change calculations;
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- environmental data;
- depressurisation logs and records;
- dewatering procedure and schematic layout of relevant facilities;
- dewatering logs and records;
- records and photographs of all leaks, if applicable.
11.0
MEASUREMENTS
1 1.1
Water Amount Measurements

The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used).
In the calculation, as per clause 12.1 of this specification, use shall be made of the geometrical
volume of the section in question. The water amount that has been let into the section shall be
measured during the pressurisation stages thorough positive displacement meters or turbine
meters.
1 1.2
Pressure Measurement
Pressure shall be measured with a dead weight tester that shall permit readings of at least 0.05
bar.
During the test, the pressure shall be recorded by means of a recording pressure gauge featuring
the following specifications:
Accuracy
Recording
Feed
Recording range
:
:
:
:
0.1% of the full-scale value

continuous on tape or disk, graph width l00 mm
20mm/h for tape diagrams, 7.50 /h for disk diagrams
to be such as to record pressure between 50% and 90% of the
diagram width.
The recording pressure gauge shall be checked by means of dead weight test at the beginning, during
and at the end of the hydrostatic test.
11.3
Temperature Measurements
a)
Water temperature shall be taken at every 2 hours through the thermocouples that have been
installed along the section under test on the pipe wall.
Further, the temperature measurement shall be taken:
-
during the filling operation

during the thermal stabilisation stage
during the hydrostatic test
The thermocouples' sensitivity shall enable temperature readings with the accuracy of 0.20C.
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b)
Water temperature shall also be measured on the pump delivery by means of a recording
thermometer throughout the filling stage.
The recording thermometer shall feature the following characteristics:
Accuracy
:
1% of the scale range
Scale
:
-100 to +400C
Recording
:
Continuous on tape or disk, diagram width l00 mm
Feed
:
20mm/ h for tape diagrams, 7.50 /h for disk diagram
c)
Ground temperature shall be taken by measuring pipe temperature at the thermocouples prior to
starting the filling operation.
d)
Environmental temperature shall be recorded from the beginning of pressurization to the end of
the test by means of a recording thermometer featuring the following characteristics:
Accuracy
Scale
Recording
Feed
:
:
:
:
1% of the scale range

00 C to +60 0C
Continuous on tape or disk, diagram width l00 mm
20 mm/ h for tape diagrams, 7.50 / h for disk diagrams.
12.0
CALCULATIONS
12.1
The theoretical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall be calculated by
means of the following formula:
Where
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12.2
The pressure change due to a water temperature change shall be calculated through the following
formula:
Where
13.0
PRECAUTIONS DURING THE TEST

In addition to all that has been expressly described in the procedures for carrying out the tests,
the following additional requirements shall be complied with:
13.1
Provision shall be made for the installation of no-admittance signs to unauthorised personnel
from the roads to the R.O.U.
13.2
Signs stating 'PIPE UNDER TEST-KEEP OFF" with local language translation shall be placed
where the pipeline is uncovered, and particularly where the provisional traps and stations are
located. Such areas shall be suitably fenced in such a way as to prevent access of unauthorised
personnel. No unauthorised personnel shall be closer than 40M to the pipeline or equipment
under test.
13.3
Provisional scraper traps shall be installed in compliance with methods and suitable location so
that their rupture cannot cause any injuries to the personnel or third parties.
13.4
The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.
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13.5
Once dewatering is over the sectionalising valves and other valve assemblies tested previously,
shall be installed at locations shown in the drawings and in accordance with the procedures
contained in the relevant specifications. All thermocouples installed in the pipeline shall be
removed and damage corrosion coating shall be repaired using Company approved materials and
procedure.
14.0
PRESERVATION OF PIPELINE
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration,
Contractor shall completely fill the pipeline with water, with sufficient quantity of corrosion
inhibitors depending upon quality of water and the period of conservation, at a pressure to be
agreed upon with the Company at a later stage. Contractor shall obtain necessary approval from
the Company of the procedure, type and quality and quantity of inhibitors used before
commencement of the works.
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FOR
PIPELINE MARKERS
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DOCUMENT NO.
S-04-02-030
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Page 1 of 5
CONTENTS
1.0
SCOPE
2.0
REFERENCE CODES AND DRAWINGS
3.0
GENERAL
4.0
AERIAL MARKERS
5.0
KILOMETER MARKERS
6.0
PIPELINE WARNING SIGN
7.0
ROW BOUNDARY MARKERS
8.0
DIRECTION MARKERS
9.0
NAVIGABLE WATER WAY PIPELINE CROSSING WARNING SIGN
10.0
SPECIAL MARKERS
REFERENCE DRAWINGS
GAIL STANDARD DRAWINGS
S-04-01-014
K.M. POST
S-04-01-015
TYPICAL ROW BOUNDARY MARKER
S-04-01-016
AERIAL MARKER
S-04-02-017
DIRECTION MARKER
S-04-02-018
S-04-02-019
NAVIGABLE WATERWAY PIPELINE CROSSING WARNING

SIGN
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DOCUMENT NO.
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1.0
SCOPE:
1.1
This specification covers the minimum requirements for supply, fabrication and
erection of pipeline markers to be installed by CONTRACTOR at various locations
along the route of a cross-country pipeline.
1.2
This specification shall be read in conjunction with the conditions of all

CONTRACTOR.
2.0
REFERENCE CODES:
Reference has been made in this specification to the latest edition of the following code:
API RP 1109
Recommended Practice for Marking Liquid

Petroleum Pipeline Facilities.
3.0
GENERAL:
3.1
CONTRACTOR shall supply, fabricate and install the Pipeline Markers along the
pipeline route. The location of markers as indicated in the approved drawings shall
be treated for guidance purpose only and the exact location of the markers shall be
based on AS BUILT drawings and as directed by COMPANY.
3.2
The pipeline markers shall be fabricated and installed in accordance with the GAIL
standard drawings included herein. Before start of fabrication of the markers, the
CONTRACTOR shall prepare and submit for COMPANY'S approval, the detailed
scheme for the marker plates as applicable for the project. All the markers shall be
painted in accordance with the requirements of Standard Specification for Shop
and Field Painting (Specification No. S-05-02-014). The painting scheme shall be
suitable for Normal Corrosive Environment.
3.3
The pipeline markers shall be installed, as far as possible, at locations such that
they do not cause any hindrance to the regular use of the land or to the traffic.
4.0
AERIAL MARKERS:
Aerial Markers shall in general be installed along the pipeline at every five (5) kilometers
intervals and at places specified by COMPANY. Refer GAIL Standard Drawing No. S-04-01016 for details.
5.0
KILOMETER MARKERS:
Kilometer Markers shall in general be installed along the pipeline at every one (1)
kilometer interval. Markers shall indicate cumulative distance in kilometers from the
reference station, as directed by COMPANY. A kilometer marker is not required, if the
relative distance between its location and any pipeline warning sign is less than 200
meters. Refer GAIL Standard Drawing No. S-04-01-014 for details.
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6.0
PIPELINE WARNING SIGN:
Pipeline Warning Sign shall in general be installed at:
National and State Highway crossings
2 Nos. min.
Other Road crossings
1 No. min.
Railway Crossings
2 Nos. min.
Minor Water Crossings (less than 15 m width) -
1 No. min.
Minor Water Crossings (above 15 m width)
2 Nos. min.
Major water crossings
2 Nos. min.
Valve station
1 No. min.
Any other location as shown in the approved drawings and as directed by

the COMPANY
Pipeline Warning Sign shall identify the existence of the pipeline and display the name of
the COMPANY, with an emergency telephone number, as shown in GAIL Standard
Drawing No. S-04-01-018.
7.0
ROU BOUNDARY MARKER:
Right-of-Use boundary markers shall be fabricated as per the drawings and shall be
installed at every 250 meters interval along the entire pipeline route. These shall be
installed on either side of the pipeline alignment to define the ROW boundary limits.
These shall also be installed at pipeline turning points to maintain the continuity of the
ROW limits. Refer GAIL Standard Drawing No. S-04-01-015 for details.
8.0
DIRECTION MARKERS:
Direction Markers as shown in GAIL Standard Drawing No. S-04-01-017 shall be installed
to identify the significant Turning Points of the pipeline during serial traverse. One
direction marker shall be installed at each Turning Point, two more direction markers shall
be installed along the pipeline alignment, one on either side of the Turning Point at 200 m
from the Turning Point.
9.0
NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN:
The Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated in accordance
with GAIL Standard Drawing No. S-04-01-019. Such Warning Sign shall be installed one
on each bank of navigable water courses at the pipeline crossing location, in lieu of the
Pipeline Warning Sign described in Clause 6.0 of this specification.
GAIL (INDIA) LTD
NEW DELHI

PIPELINE MARKERS
DOCUMENT NO.
S-04-02-030
REV-0
Page 4 of 5
10.0 SPECIAL MARKERS:

As directed by COMPANY, special markers shall be installed at location where following
changes take place:
Change in pipeline diameter and wall thickness.
Change in type of pipe
Change in class / zone locations for pipelines conveying gas and HVP
products.
The above data may be provided on other types of marker (except ROU boundary
marker), if the relative distance between the two does not exceed 100m.
GAIL (INDIA) LTD

NEW DELHI

PIPELINE MARKERS
DOCUMENT NO.
S-04-02-030
REV-0
Page 5 of 5
FOR
DOCUMENTATION FOR
PIPELINE CONSTRUCTION
GAIL (INDIA) LTD

NEW DELHI

DOCUMENTATION FOR PIPELINE
CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 1 of 9
CONTENTS
1.0
SCOPE
2.0
RECORDS
3.0
AS-BUILT DRAWINGS AND PIPE BOOK
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 2 of 9
1.0
SCOPE:
1.1
This specification covers the minimum requirements of various records, reports and
drawings for all aspects of pipeline construction to be prepared by the
CONTRACTOR and submitted to the COMPANY at intervals as described in this
specification and as directed by the COMPANY.
1.2
All documents required to be prepared and submitted by the CONTRACTOR as per

this specification shall be in addition to the various reports, records, methodology
statements, calculations, drawings etc. to be submitted by the CONTRACTOR for
COMPANY'S record, review or approval as per the requirements of all other
specifications included in the CONTRACT between the COMPANY and the
CONTRACTOR.
1.3
This specification shall be read in conjunction with the conditions of all

CONTRACTOR.
2.0
RECORDS:
The CONTRACTOR shall submit daily, weekly, monthly and after completion, to the
COMAPANY, various records and reports for COMPANY'S documentation purpose during
and immediately after the construction. This shall as a minimum include, but not limited
to the following:
2.1
2.2
Daily
Separate progress reports of all crews
Daily welding results and repairs
Actual weather conditions
Application for deviations, if any
Accidents
Damages
Activities required from COMPANY
Materials Receipts
Urgently required materials

Weekly
Up-to-date list of confirmed Site Instructions issued by COMPANY
Materials 'taken over'
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 3 of 9
2.3
Materials defects and repairs
Outstanding activities of COMPANY
List of installed markers, chainage
Required approval form COMPANY
Progress planned
Reports of manning of all crews, equipment and plant
Reports of equipment and plant
Reports of accidents
Reports of damages
Reports of Acquired Releases, Permits etc.
Prices variations
Required materials for next month
Monthly
2.4
Progress report for payment, safety report, report of accidents, security

reports, health and environment report, material balance, approved
deviations.
Further, CONTRACTOR shall supply for approval, if required, to the COMPANY with
document such as but not limited to:
Organogram for construction of work
Bio-data of key personnel (including foremen)
(Revised) list of address of personnel in particular of medical staff, safety

and security officers.
(Revised) list of approved coaters
(Revised) list of approved sub-contractors
Time schedule
Acquired permits and/or approval from Authorities, if any.
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 4 of 9
Minutes of meeting with COMPANY with comments, if any.
Material certificates, material receipt.
Guarantees from Vendors and sub-contractors
Calculations, temporary works, buoyancy, blasting.
Drawings issued by CONTRACTOR.
Vendor drawings.
As-built drawing of route maps, alignment sheets, detail drawings and

isometric drawings,
Procedures such as surveying, stacking, fencing.
Welding procedure qualification record, radiographic procedure qualification,

welder qualification
Coating procedure.
Installation of crossings.
Hydrostatic testing
Blasting
Radiographic report along with original radiographs
Pipe and welding book
Material records and Accounting book

Reports
Material tests (coating, welding, painting)
Computerized Potential Logging Test
Water samples
Cleaning, Pigging Report before hydrostatic test
Hydrostatic test
Calibration test
Blasting trials
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 5 of 9
Equipment certificates (dead weight tester, instruments, vessels,

equipment)
Manuals
Major water crossings -
Waste disposal
Disposal of water after hydrostatic test.
2.5
The CONTRACTOR shall submit to COMPANY, colour photographs (hard copy as

well as digital format) taken through digital camera (having resolution > 1 million
pixels) of various construction activities/operations at regular intervals. Size,
number and frequency of the photographs shall be mutually agreed upon between
the CONTRACTOR and the COMPANY. The CONTRACTOR shall make video
recordings of all operations right from the start of construction till the completion
of the work, covering to the extent as instructed by COMPANY and submit to
COMPANY. Upon completion of the work, the CONTRACTOR shall submit edited
master tape plus six copies of video recording in VCD / DVD formats or any other
format ordered by the COMPANY. The duration of video recording shall be of
hour and shall cover all aspects of the job.
3.0
AS-BUILT DRAWING AND PIPE BOOK:
3.1
General
The CONTRACTOR shall prepare "As-built' drawings of all by or on behalf of
COMPANY issued drawings and of all CONTRACTOR work drawings including
vendor drawings, such as but not limited to:
For pipeline section:
Route maps
Alignment sheets
Detail drawings (road, railway, minor water crossings, major water crossing,
valley crossings)
Isometric drawings of installations
Special installation.
Further CONTRACTOR shall prepare a pipe Weld Book.

If required by the COMPANY, the CONTRACTOR shall update the diskettes for
drawings issued for construction of the job. -
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 6 of 9
3.2
"As-built" Drawings:
The CONTRACTOR shall prepare a complete set of "As-built" drawings. From the
start of construction, the CONTRACTOR shall, on daily basis, process any changes
in two sets of drawings. Deleted parts shall be indicated in red, new parts in blue,
remarks in green and unchanged parts in yellow. Said drawings shall be kept at
site and shall be available to COMPANY at all times. The CONTRACTOR shall
prepare "As-built" drawings based on these data. On completion of the work, one
revised film transparency of all drawings made "As-built" by CONTRACTOR
containing the "As-built" information as well as one complete set of CD ROM
containing "As-built" drawings shall be handed over to COMPANY.
The CONTRACTOR shall prepare and submit a specimen of the layout of the
drawings for COMPANY'S approval.
The required measurement for "As-built" drawings shall be executed by the
CONTRACTOR by experienced and qualified surveyors.
The surveyors shall daily take care of all measurements required such as but not
limited to:
Horizontal location of pipeline with regard to deviation and Permanent Grid

Pillars.
Vertical level with regard to Mean Sea Level of pipeline and grade.
Location and type of bends, fittings etc. and grades, points of intersection.
Changes of wall thickness, materials.
Location and details of valves, insulating joints, fencing.
Location and details of road, railway, water crossing, suspension bridges.
Location and details of crossing pipes, vents.
Location and type of coating.
Location and type of weighing, anchoring.
Location and type of markers.
Location of further appurtenances (Pig-signalers).
Location of ROU and of pipeline with respect of ROU.
Type of soil.
Type of rock.
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NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 7 of 9
Type of blasting and ripping
Sand Padding
Type of Road Pavement
Details of Bank protection, No. of Insulators, seals
The CONTRACTOR shall also prepare isometric drawings of installation (facilities)

etc. for which the data as mentioned in or required for the Pipe and Welding Book
can be identified and these drawings can also be used for material accounting.
3.3
Name plates of Equipment:

All permanent equipment supplied and installed by CONTRACTOR shall be provided
with plates by CONTRACTOR. All texts shall be submitted to COMPANY for approval
before plates may be manufactured.
3.4
Pipe Book:
Every page of the Pipe and Welding Book shall mention:
Data relevant to the project and section thereof
Sequential number
Length brought forward (for pipes and other materials)
Length to bring forward (for pipes and other materials)
Alignment sheet number and at least the location thereon of two welds on
every page of the Pipe Book.
Further,
Diameter of pipeline
Length of each pipe
Wall thickness
Pipe number
Heat number, certificate number
Cut and re-numbered pipe ends
Coating
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 8 of 9
Date of stringing
Data of welding
Direction of working
Weld number
Welder number
Type of welding, electrodes, diameter of electrodes etc.
Heat treatment
Equipment used for radiography
Limits of water crossings.
Test pressure and date of test.
In order to achieve this, the CONTRACTOR shall identify all pipe elements. Sample
format of Pipe Book shall be submitted for COMPANY approval.
3.5
As-Built Documents:
The CONTRACTOR shall prepare all documents in the prescribed format as
indicated below. In addition to the hard copy, three copies of final documents shall
also be submitted in electronic media i.e. CD ROM.
Software used for the preparation of these documents shall be as follows:
Type of document Software
a) Reports MS Word (Windows 98 / 0ffice 2000 / office 2003 / XP)
b) Drawings AutoCAD Release 14 and above.
For the purpose of preparation of As-built drawings, CONTRACTOR shall update
the "Issued for Construction" drawings issued by the COMPANY. It shall be the
CONTRACTOR'S responsibility to convert the drawings furnished by the COMPANY
in hard copy into CAD drawings including scanning, digitizing and converting the
drawings into a suitable format compatible with the AutoCAD Release 14 and
above. As-built drawings shall be prepared only on AutoCAD.
GAIL (INDIA) LTD

NEW DELHI

CONSTRUCTION
DOCUMENT NO.
S-04-02-031
REV-0
Page 9 of 9
FOR
BLASTING
GAIL (INDIA) LTD

NEW DELHI

BLASTING
SPECIFICATION
S 04 02 032
REV-0
Page 1 of 11
GAIL (INDIA) LTD

NEW DELHI

BLASTING
SPECIFICATION
S 04 02 032
REV-0
Page 2 of 11
1.0
SCOPE
1.1
This specification covers the minimum requirements for materials, personnel,

transportation, storage and use of explosives for grading of Right of Use (ROU) and
excavation of trenches for the burial of pipelines in rocky terrain.
1.2
This specification does not cover the construction or operation of permanent

magazines.
1.3
This specification applies to on-shore pipeline installation.
2.0
REFERENCE DOCUMENTS
2.1
The following National and International regulations and codes shall be used:
BS 5607
NFPA-495
Safe use of explosive in construction Industries

:Manufacture, Transportation, Storage & Usage of Explosive
Materials.
National and Local Laws/Regulations

Applicable Safety Rules of Chief Inspector of Explosives, Nagpur
IS 4081
Safety Code for Blasting and related drilling operations
3.0 GENERAL
3.1
The CONTRACTOR shall acquaint himself and comply with all the applicable local laws
and regulations concerning storing, handling and the use of explosives. All such laws,
regulations and rules etc., as enforced from time to time shall be binding upon the
CONTRACTOR. National/Local Laws and Regulations shall take precedence over this
specification in the event of conflict. All conflicts shall be brought to the notice of the
COMPANY.
3.2
The requirements stated herein however in no way relieve the CONTRACTOR of this
responsibility of carrying out safe blasting operations and shall be solely responsible for
damages and claims thereof.
3.3
The use of explosives requires an approval from the Chief Inspector of Explosives
and/or his authorized Inspector. It shall be the responsibility of the CONTRACTOR
to obtain all such permits and observe all requirements regarding the safe storage,
handling and use of explosives. All expenses incurred in this regard shall be to
CONTRACTOR'S account.
GAIL (INDIA) LTD
NEW DELHI

BLASTING
SPECIFICATION
S 04 02 032
REV-0
Page 3 of 11
3.4
Contractor shall inform the COMPANY in writing at least four(4) weeks prior to planned
use of explosives.
3.5
Contractor shall notify the COMPANY prior to any blasting in the proximity of overhead
power lines, roads, communication lines, pipelines, utility services or other services and
structures above and below ground. Before, starting blasting operations, local
authorities and owners of utilities shall be consulted to check on the presence of
services which could be damaged and their approval obtained to undertake blasting
operations. The distances to nearest structures(houses, offices, factories) or service
shall also be taken into consideration when planning blasts so that ground vibration and
air-over pressure is kept within acceptable levels as given in section 11.0 of this
specification.
3.6
CONTRACTOR shall prepare an Explosives Handling and usage Procedure for the
information of the COMPANY which shall incorporate the following:
-
Individual procedure and calculations
Nature of blasting operations, including hole diameter, depth and presence of

cavities
Rock characteristics
Type of explosives
Temperature likely to be encountered in use
3.7
No blasting is allowed within 20 m of any above ground or underground structure or

facilities. No blasting is allowed within 200 m of overhead power lines/cables unless
specifically approved by the Authorities having jurisdiction over it and COMPANY.
4.0
MATERIALS
4.1
All materials such as explosives, detonators, fuses, tamping materials etc. that are
proposed to be used by the CONTRACTOR in blasting operations, shall be as Approved
for use in the Country.
4.2
All electric detonators used in the blast shall be of the same electrical sensitivity and
be produced/procured from the same manufacturer.
4.3
The detonators used shall be capable of giving effective blasting of the explosives.
Damaged explosive materials shall be destroyed by a responsible person as per
manufacturer's instructions or returned to the manufacturer.
GAIL (INDIA) LTD

NEW DELHI

BLASTING
SPECIFICATION
S 04 02 032
REV-0
Page 4 of 11
4.4
No explosive material shall be abandoned.
4.5
All blasting materials and testing equipment shall be regularly tested for correct
performance. The intervals between test shall be decided after consideration of the
local factors, but tests shall always be carried out if the blasting materials and/or test
equipment have been subjected to abnormal conditions, or following misfires.
Guidelines/recornrnendations of the manufacturer shall be adhered to.
4.6
All packaging and.other waste materials gathered together during blasting operation
shall be burnt after the blast has been fired.
The burning site shall be chosen at a safe distance with due respect to prevailing wind
strength and direction, at least 100 meters from explosives stores and other premises. A
minimum of two fire extinguishers shall be on hand during burning activities.
5.0
PERSONNEL
5.1
Excavation by blasting will be permitted only under personal supervision of competent

and licensed persons and by trained workmen.
5.2
The storage of explosives shall be in the charge of a person approved by the COMPANY.
COMPANY may, if necessary, ask police inquiries being made as to his reliability,
antecedents etc.
6.0
STORAGE OF EXPLOSIVES
6.1
The CONTRACTOR shall build a magazine for storing the explosives. The site of the
magazine, its capacity and design shall be subject to approval by the COMPANY and the
inspector of Explosives before the fabrication is taken up. As a rule the explosives
should be stored in a clean, dry, well ventilated, bullet proof and fire proof building, at
an isolated site. Adequate security shall be provided to ensure no unauthorized entry
into the magazine. A notice shall be hung next to magazine entrance prohibiting entry
of unauthorized persons.
6.2
CONTRACTOR shall comply with National/Local Regulations and specifications for

truck mounted mobile explosives store. Mobile stores shall only carry ONE DAY'S
Explosives requirements and shall be parked overnight inside the compound at the
authorized magazine.
6.3
All safety precautions and necessary equipment for maintenance, operation of mobile
stores, as required by local authorities or regulatory bodies shall also be
installed/provided on the Mobile Store.
6.4
A careful and day-to-day account of all explosives shall be kept by the CONTRACTOR in
a register and in an approved manner. The register shall be produced by the
GAIL (INDIA) LTD
NEW DELHI

BLASTING
SPECIFICATION
S 04 02 032
REV-0
Page 5 of 11
CONTRACTOR, for the inspection of the COMPANY/Inspectorof Explosives when so

required by the later.
Any loss, damage or theft shall be reported immediately to the necessary local authorities and
to the COMPANY.
6.5
The magazine shall on no account be opened during or on the approach of a

thunderstorm and no person shall remain in the vicinity of the magazine during such
period.
6.6
Magazine-shoes without nails shall, at all times, be kept in the magazine, and a woodtub or cement trough, filled with water shall be fixed near the door of the magazine.
6.7
Persons entering the magazine must put on the magazine-shoes.

1)
not to put their feet on the clean floor unless they have magazine-shoes on.
11)
not to allow the magazine-shoes to touch the ground outside the clean floor.
111) not to allow any dirt or grit to fall on the clean floor.
6.8
No matches or inflammable material shall be allowed in the magazine. Light shall

be obtained from an electric storage battery lamp.
6.9
No person having articles of steel or iron on him shall be allowed to enter the magazine.
No tools or implements other than those of copper, brass, gun metal or wood shall be
allowed inside the magazine.
Oily cotton, rags, waste and articles liable to spontaneous ignition, shall not be allowed inside
the magazine.
6.10
Boxes of explosives shall not be thrown down or dragged along the floor and shall be
stacked on wooden trestles. Open boxes of explosives shall never be expcsed to the
direct rays of the sun. Empty boxes or loose packing materials shall not be kept inside
the magazine.
6.11
The magazine shall have a lightning conductor, which shall be got tested at least
periodically, by an officer authorized by the COMPANY, the testing fee shall be to the
CONTRACTOR'S account.
6.12
The magazine shall be inspected periodically by an officer representing the COMPANY,

who will see that all the rules are strictly complied with. He will notify all omissions etc.
to the CONTRACTOR, who shall rectify the defects within a period of 3 days from the
GAIL (INDIA) LTD

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BLASTING
SPECIFICATION
S 04 02 032
REV-0
Page 6 of 11
date of receipt of the notice, failing which the COMPANY mat take whatever actions it
considers suitable.
7 .O
PREPARATION OF EXPLOSIVES
7.1
CONTRACTOR shall submit the following procedure for INFORMATION of the

COMPANY as a minimum.
-
Loading of explosives
Drilling of new holes and extending existing holes
Handling of explosives at site
Tamping explosives into holes
Machines, tools and cables required
Initiation of blasting
Safety of personnel
Vibration control
Blast pattern and shot size establishment
Misfires
Emergency procedures
7.2
Trial blasts in conjunction with vibration recording shall be carried out for each rock and
trench type, in order to assess rock breakability and vibration levels. These trial blasts
shall be carried out prior to actual trench blasting of the pipeline route.CONTRACTOR
shall conduct trial digs as directed by COMPANY in order to check suitability of the
lasting pattern and to measure vibration levels to ensure vibration levels are below the
allowable maximum.
7.3
"Weight per Distance Tables" shall be drawn up from these trials.
7.4
The detonators shall never be forced into the primer cartridge. It shall be inserted in a
hole made by a wooden, copper, brass or aluminum pricker. The detonator shall be
firmly embedded in the primer so that it is not pulled out of place during loading.
7.5
Detonators shall be activated electrically. In proximity of electric over-head power lines,

CONTRACTOR may use non-electric system with the approval of COMPANY. Fly rock
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BLASTING
SPECIFICATION
S 04 02 032
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Page 7 of 11
shall be minimized by the use of approved blast mats and by careful selection of shot
size and drill hole configuration.
7.6
Use of explosives is prohibited in areas exposed to flammable gasses or dust.
7.7
Explosive and detonators shall be carried in separate boxes, tightly closed, and
transported separately. For the conveyance of primers special containers shall be used.
7.8
Explosives shall be stored and used chronologically to ensure that the ones received
earlier are being used first.
7.9
A make-up house shall be provided at each working place in which cartridges shall be
made up by experienced men as required. The make-up house shall be separated from
other buildings. Only electric storage battery lamps shall be used in this house.
7.10
No smoking shall be allowed in the make-up house.
8.0
PREPARATION OF PRIMERS
The primers shall not be prepared near open flames or fires. The work of preparation of
primers shall always be entrusted to the qualified and approved personnel. Primers shall
be used as soon as possible after they are ready.
9.0
CHARGING OF HOLES
9.1
The work of charging shall not commence before all the drilling work at the site is
completed and the COMPANY has satisfied itself to that effect by actual inspection.
9.2
The lead wires shall be kept away from conductors or sources of stray current While
charging, open lampslflames shall be kept away.
9.3
Only wooden tamping rods without any kind of metal on them shall be used.
9.4
Only one cartridge shall be inserted at a time and gently inserted to the required depth
with the tamping rod. The sand, clay or other tamping material used for filling the hole
completely shall not be tamped too hard.
9.5
Blasting shall not take place after sunset or before sunrise unless specific approval is
first obtained by CONTRACTOR from local authorities and the COMPANY.
9.6
The site of blasting operations shall be prominently demarcated by red danger flags.
The order of fire shall be given only by the supervisor-in-charge of the work and this
order shall be given only after giving the warning signal three times, so as to enable all
the labor, watchmen etc. to reach safe shelter and after having ascertained that nobody
is within the danger zone.
GAIL (INDIA) LTD
NEW DELHI

BLASTING
SPECIFICATION
S 04 02 032
REV-0
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9.7
A buegle with a distinctive note shall be used to give the warning signals. The buegle
shall not be used for any other purpose. All the labor shall be made acquainted with the
sound of the buegle and shall be strictly warned to leave their work immediately at the
first warning signal and to take safe shelters, and not to leave the shelters until the all
clear signals have been given.
9.8
All the roads and foot-paths leading to the blasting area shall be watched
10.0
ELECTRICAL FIRING
10.1
Only the Supervisor-in-charge shall keep the key of the firing apparatus and shall keep
it always with himself.
10.2
Special apparatus shall be used as source of current for the firing operations. Power
lines shall not be tapped for the purpose.
10.3
The firing cable shall have a proper insulating cover so as to avoid short circuiting due
to contact with water, metallic parts or rock.
10.4
The use of earth as a return line shall not be permitted.
10.5
The firing cable shall be connected to the source of current only after ascertaining that
nobody is in the area of blasting
10.6
Before firing, the circuit shall be checked by a suitable apparatus.
10.7
After firing, whether with or without an actual blast, the contact between the firing
cable and the source of current shall be cut off before any person is allowed to leave
the shelter.
10.8
During storms, charging with electrical detonators shall be suspended. The charges
already placed into the holes shall be blasted as quickly as possible after taking all the
safety precautions and giving necessary warning signals. If this is not possible, the site
shall be abandoned till the storm has passed.
11.0 VIBRATION RECORDING

11.1
CONTRACTOR shall use COMPANY approved vibration recording system capable of

measurement in three axes (tri-axial). The device shall have an accuracy of 0.0025 mm
and a resonance of 2 Hz.
The device shall measure both frequency and amplitude of vibration.
11.2
All the measurement devices shall be calibrated by an APPROVED certification
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body.
11.3
Particle velocity shall not exceed the following:
11.3.1
Areas not with 500 m of existing facilities

-
11.3.2
50 mm/sec at a surface measured distance of 15 m from trench center line.

Areas with existing buried or above ground facilities within 500 m.
20 mm/sec. At a surface measured distance from the trench center line towards
the nearest existing facilities.
11.4
The particle velocity levels are provided for the guidance only, CONTRACTOR
shall be responsible and liable for any injury to life or damage to property/facilities.
11.5
Air-over pressure/sound levels shall be limited to 100 db in inhabitated areas.
12.0 MISFIRES
12.1
If it is suspected that part of the blast has failed to fire, or is delayed, sufficient time
shall be allowed to lapse before entering the danger zone. When fuse and blasting caps
are used, a safe time should be allowed and then the Supervisor alone shall leave the
shelter to see the misfire.
12.2
Drilling near the hole that has misfired shall not be permitted until one of the two
following operations have been carried out by the Supervisor:
I)
The Supervisor should very carefully (when the tamping is of damp clay) extract
the tamping with a wooden scraper or jet of water or compressed air (using a
pipe of soft material) and withdraw the fuse with the primer and detonator
attached. A fresh primer and detonator with fuse shall then be placed in this hole
and fired.
II)
The Supervisor shall get one foot of the tamping cleaned off and indicate the
direction by placing a stick in the hole. Another hole may then be drilled at least
9" away and parallel to it, this hole should then be charged and fired. The
balance of the cartridges and detonators found in the muck shall be removed.
12.3
The Supervisor shall at once report to the office all cases of misfire, the cause of the
misfire and the steps taken in connection therewith.
12.4
If a misfire has been found to be due to defective detonator, or explosive, the whole
quantity from the box from which the defective articles were taken must be returned to
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SPECIFICATION
REV-0
S 04 02 032
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the manufacturer for inspection to ascertain whether the whole box contains defective
materials.
12.5
Re-drilling the holes that have misfired either wholly or partly shall not be permitted.
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SPECIFICATION
REV-0
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DETAILED PIPELINE ROUTE SURVEY
(ONSHORE)
GAIL (INDIA) LTD

NEW DELHI

(ONSHORE)
DOCUMENT NO.
S-04-02-033
REV-0
Page 1 of 17
CONTENTS
1.0
SCOPE
2.0
REQUIREMENTS
3.0
PRELIMINARY AND LOCATION SURVEYS
4.0
BENCH MARKS
5.0
CROSSINGS
6.0
ACCURATES IN MEASUREMENT
7.0
CHAINAGE
8.0
MEASUREMENT OF HORIZONTAL ANGLES
9.0
PROFILES
10.0
BUILT-UP AREAS
11.0
AZIMUTH OBSERVATIONS
12.0
SURVEY NOTES, OBSERVATIONS & COMPUTATIONS
13.0
MAPS AND DRAWINGS
14.0
PRESENTATION OF FIELD SURVEY DATA

ANNEXURE I
SPECIFICATION FOR SOIL INVESTIGATION
ANNEXURE - I1
ADDITIONAL REQUIREMENT FOR GAS PIPELINES DETERMINATION OF POPULATION DENSITY INDEX &
CLASS LOCATION
ANNEXURE - I11 -
ADDITIONAL REQUIREMENT FOR HIGH VAPOUR

PRESSURE (HVP) LIQUID PETROLEUM PIPELINES ZONE LOCATION
ANNEXURE IV
PIPELINE ROUTE SURVEY DATA SHEET
ATTACHMENTS
SAMPLE FORMATS
GAIL (INDIA) LTD

NEW DELHI
1.
PIPELINE ROUTE MAP
2.
ALIGNMENT SHEET

(ONSHORE)
DOCUMENT NO.
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1.0
SCOPE:
This specification covers the minimum requirements of topographical survey along the
pipeline route including locating the centre-line of pipeline alignment on the ground,
constructing survey monuments, field measurements for planimetry and profiles and
preparation of drawings and documents.
This specification also covers the minimum requirements for soil investigation for the
purpose of visual engineering classification of soil along the pipeline route.
2.0
REQUIREMENTS:
2.1
All survey works shall be performed by or under the supervision of a qualified land
surveyor.
2.2
All measurements shall be in metric units.
2.3
The readings and noting shall be neat, legible and scorings and over-writing shall
be duly initialed by the Surveyor.
3.0
PRELIMINARY AND LOCATION SURVEYS:

The Surveyor is expected to make himself aware of the general conditions of the
terrain before starting detailed survey.
3.1
Alignment and location surveys:

A preliminary survey for locating the centre-line of pipeline alignment on the
ground shall be carried out as follows:
3.1.1 Surveyor shall make a preliminary survey along the route of the proposed pipeline
to establish and flag control points.
3.1.2 Surveyor shall locate and identify the existing features or obstructions along the
route that are not shown in available maps or drawings.
Archeological sites, reserved forests, environmentally sensitive areas, mining sites
and built up areas shall be avoided.
3.1.3 Where it becomes apparent that a better route could be followed, the Surveyor
shall consult the COMPANY / ENGINEER for authorization to make a change.
3.1.4 Turning Points (TPs) shall be located by Surveyor in consultation with
COMPANYIENGINEER considering the following:
To avoid obstruction along the line, by ranging on ground and shifting the Turning
Points if need be.
Check for terrain gradient by using hand clinometer
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Ensure proper angle of crossing by keeping as nearly right angle (to road /rail /
streams, etc.) as possible. The right angle may be laid on ground by using a chain
or string lengths in ratio of 3,4 and 5.
To check from construction point of view and avoid objects like power, telephone
and telegraph poles, walls, tube wells or such other structures falling in the strip of
land, 25M on either side of pipeline alignment.
3.2
Staking of pipeline route
3.2.1 The pipeline defining trench centre line shall be staked by placing suitably painted
marker stakes at Turning Points (TPs) and at Intermediate Points (IPS) between
consecutive TPs.
All Turning Points (TPs) and intermediate points are referred as Intersection Points.
The pipeline centre line shall be staked on the ground as follows:
First, the Turning Points (TPs) shall be staked on the ground. After locating and
marking the TPs, the intermediate points shall be staked while measuring slack
distance. The staking shall normally be done at intervals of 500 M along the centre
line of the pipeline.
3.2.2 The Intersection Points shall be serially numbered form the starting point. The
serial number of each Intersection Point shall be boldly inscribed on the marker
stake. In addition, the Turning Point (TP) marker stake shall identify the Turning
Point reference number from the starting point.
3.2.3 For Intermediate Points (IPS) letter "P" shall precede the serial number of the
intersection Point marker. For Turning Points, the letters "TP" shall precede the
Turning Point reference number, and the letter "P" shall precede the serial number
of the Intersection Point.
3.2.4 The marker stakes at Turning Points (TPs) shall be referred with three reference
stakes around the TP. The reference stakes shall carry the Turning Point reference
number and their respective distance from the TP marker stake.
3.2.5 Change in direction of line shall be marked on the TP marker stakes. In addition,
direction markers near TPS and other locations shall be placed wherever
necessary.
3.3
Stakes and Markers
3.3.1 All marker stakes shall be pre-cast reinforced concrete blocks having dimensions
150 x 200 x 800 MM deep, and shall be buried to a depth of 500 MM.
The exposed surface of the blocks shall have a smooth finish and shall be painted
with 'Post Office' red paint. All letters and figures shall be paint marked on the
surface of the blocks in white.
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3.3.2 On the top surface of the reinforced concrete blocks, a cross inside a circle shall be
engraved at the centre or a nail shall be put centrally inside an engraved circle, to
indicate the exact position of the Intersection Point. The circle shall be of
approximately 50MM diameter.
3.3.3 Surveyor can, however, propose to the COMPANYIENGINEER other types of stakes
/ markers which are better suited to site conditions.
4.0
BENCH MARKS:
4.1
Permanent Bench Marks (BM) approx. every 5 KMs or permanent structures on or

off the Right-of-Use (ROU) shall be established and described.
4.2
Additional permanent bench marks shall be established near the major pipeline
crossing sites.
4.3
Location of Bench Marks shall be established in the field by using reinforced

concrete blocks similar to pipeline marker stakes described in clause 3.3.1 of this
specification. Exact position of BM shall be marked by a cross inside a circle or a
nail put centrally inside an engraved circle on the top surface of the concrete block.
The reduced level of the BM shall be paint marked on the concrete block. Letters
"BM" shall precede the reduced level of bench mark recorded to the second place
of decimal.
4.4
Accuracy of the reduced levels of the Bench Marks shall be verified wherever
possible by checking levels with the nearest permanent Bench Mark established by
Survey of India.
5.0
CROSSINGS:
5.1
General
As far as possible, crossings shall be made at right angles. The Surveyor shall
record the angles of crossing for all fences, property lines, utilities, roads, railways,
canals, streams, etc. that are crossed. In addition, the true bearings of the
centerline of the road, railway, canal, as well as that of the pipe centre-line shall be
recorded. Turning Points (TPs) provided near crossings shall be located, at least
50m from the crossing's boundaries, in stable and firm ground.
5.2
Railway Crossings
The angles for all railway crossings shall be as close to 90 degrees as possible, but
in no case less than 85 degrees to the centre-line of the railway.
5.3
Primary Road Crossings

Primary roads are the National & State Highways, all-weather roads (paved /
unpaved) and roads providing access to major installations. The angle of crossings
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shall be as close to 90 degrees as possible, but in no case less than 80 degrees to

the centre line of the road.
5.4
Secondary Road Crossings

The angles of crossing for secondary roads shall be as close to 90 degrees as
possible, but in no case less than 45 degrees to the centre-line of the roads. All
seasonal roads, unpaved village roads, cart-tracks, etc. come under this category.
5.5
River / Stream / Nala Crossings

These crossings shall be established as close as possible to the locations shown on
the route map. Crossings shall be located in a comparatively straight reach of the
river where the banks are stable and there is sufficient area for construction. Angle
of crossing shall be as close to 90 degrees as possible.
5.6
Canals / Drainage Ditch Crossings

The angle of crossing shall be as close to 90 degrees as possible but in no case
less than 60 degrees to the centre-line of the canal / drainage ditch. Crossings
shall be located where there is no evidence of slumping or erosion of banks, or
bed.
5.7
Utility Crossings
Utilities crossed shall be located at their centerlines with stakes containing station
numbers in the survey. The angle or crossings shall be measured and locations
established relative to their above-ground facilities. The names and sizes of all
utility lines shall be included in the survey notes. In the cases of overhead power
and telephone lines, the distance to the poles and towers on each side of the
survey line shall be measured, and the numbers of poles or towers noted. Line
voltage shall also be recorded. Where possible, the survey shall be established so
that there is a minimum distance of 50 meters from the survey line to the nearest
High Tension pole or tower.
Underground utilities shall be located as far as possible and staked for a minimum
distance of 25 meters on each side of the survey line.
6.0
ACCURACIES IN MEASUREMENT:
6.1
Surveyor shall incorporate corrections to the linear ground measurement due to

standard errors, variations from standard temperature and pull.
6.2
The error for angular closure for the work shall not exceed one minute per station
and for linear measurements it shall be read to the nearest 0.005 M.
6.3
The error on closure for measurements on vertical distance to establish bench

marks shall not be more that 24K millimeters (where 'K' is the linear distance in
KM). The observations for measurement of vertical distances on bench marks shall
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be read to accuracy to the nearest 5 MM and for Inter section Points and other
points along the pipeline route and at crossings to the nearest 10 MM. The error of
misclosure in vertical distance shall be distributed linearly.
6.4
Azimuth checks shall be made by observations of the sun or Polaris at intervals of

15-20 Km. These observations of bearings together with deflection angles shall be
recorded in survey notes.
Azimuth misclosure based on bearings with observed angles at Turning Points shall
be equally distributed over the number of stations observed in between. Accuracy
of azimuth observations shall be acceptable if the three deductions agree within
one minute.
7.0
CHAINAGE:
7.1
Slack distance measurement will be made using 50 M steel tape or 30 M chain.

However, in case of abrupt slope change the tape / chain is straightened parallel to
the probable grading.
7.2
7.3
Distance between Intersection Points staked along the pipeline route shall be
measured and recorded. In addition, distance between level points shall also be
measured and recorded.
Chaining will be continuous in the direction of survey.
7.4
The true bearing of all straights shall be observed and recorded.
7.5
Data on nature of terrain, viz. sandy, stony, vegetation, etc. and type of ground
will also be recorded along with chainages of change points.
7.6
Check on distance measurements will be by stadia method at the time of levelling.
7.7
Standard chain survey format will be used for record keeping.
8.0
MEASUREMENT OF HORIZONTAL ANGLES:

Horizontal angles are measured to indicate the change in direction of alignment
and specify the horizontal bend at the Turning Points.
8.1
Theodolite, reading direct to 10 seconds or better, shall preferably be used. Angles

shall be measured clockwise from back station to fore-station. Mean of two
readings-one on face left and other on face right shall be taken as the horizontal
angle.
8.2
The line at both ends shall be tied to the grid control system being used for end
facilities. True bearing at the beginning, end and every 15-20 KM shall be observed
to keep a check on errors in angular measurements.
9.0
PROFILE:
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9.1
The continuous profile of the proposed pipeline route shall be established from the
reduced levels taken.
i)
At the starting point
ii)
At all Turning Points (TPs)
iii)
At all Intermediate Points staked on the ground,
iv)
At all points on the pipeline route where there is a change in slope.
9.2
When the terrain is flat, reduced level shall be additionally recorded along the
pipeline route at 100m interval.
9.3
When the terrain is undulating observation of reduced level shall be made at a

sufficient number of points so as to give an accurate plotting of the ground profile
along the route.
9.4
For road and railway crossings, the reduced levels shall be recorded at all points
along the pipeline alignment wherever there is a change in slope within the entire
width of the Right of-Use of the road/ railway. CONTRACTOR shall prepare a
detailed drawing for the crossing in scale 1:100 (in both horizontal and vertical
directions) which shall be truly representative of the crossing profile.
9.5
For river / stream/ nalla / canal crossings, levels shall be taken at intervals of 5M
up to 30M beyond the highest banks on both sides. Levels shall be taken at
closer intervals, if there is a change in slope. CONTRACTOR shall prepare a
detailed drawing for the crossing in scale 1 : 100 (in both Horizontal and Vertical
directions) which shall be truly representative of the crossing profile.
9.6
In right-of-use having slope across the pipeline alignment, as encountered in hilly

areas, Ghat regions, ravines and other similar areas as directed by COMPANY,
cross-sections at 50 M interval and for a length of 25 M on either side of the
pipeline alignment shall be observed and recorded.
9.7
For major water crossing sites, cross section as above shall be observed at both
banks.
9.8
Method of RISE and FALL shall be used to compute reduced levels of various
points. Check on computation shall be made by using the following formula:
Back site - Fore Site = Rise - Fall = First R.L. - Last R.L
9.9
Maximum misclosure shall not exceed 24K MM where 'K' is the distance in KMs.
Maximum length of line of sight shall not exceed 100 M.
9.10
All levels shall be with respect to Mean Sea Level (MSL).
10.0 BUILT-UP AREAS:

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10.1 Monuments and Properties

The pipeline alignment shall run clear of the existing monuments, properties and
structures etc., as indicated in Pipeline Route Survey Data Sheet (Annexure-IV).
For congested areas, closer distance may be adopted; however, location shall be
approved by COMPANY / ENGINEER.
10.2 Parallel Alignment
The pipeline alignment wherever runs parallel to an existing or planned under /
above ground facility will be treated as parallel alignment. For underground
facilities surveyor shall identify and locate them with suitable special ground laths.
The following clearances shall be observed in case of parallel alignment defined
above.
Between existing/planned electrical power cables / lines and the proposed

line - 50.0 meters
Between existing / planned communication cables / lines and the proposed

line - 25.0 meters
10.3 Parallel Encroachment

Unless otherwise stated, when the pipeline alignment runs generally parallel to a
road or railway it shall be kept sufficiently clear of the Right of Way limits of the
facility.
11.0 AZIMUTH OBSERVATIONS
Azimuth control shall be maintained by observation of azimuth at every fifteen to
twenty kilometers by closing the traverse on existing control points. Azimuth may
be obtained by making observations to sun or star depending upon the location of
the area and direction control. In case of azimuth from sun, the computed values
must be within one minute. Incase of stars the computed values should agree
within 10 to 15 secs.
Horizontal misclosure between two azimuth stations shall be equally distributed
among TPs in between.
12.0 SURVEY NOTES, OBSERVATIONS AND COMPUTATIONS:
12.1
The procedures followed both for field and office calculations shall be such that the
results obtained shall be readily understood and retraceable.
12.2
All up-to-date notes and observations related to the basis for determination of
boundary lines and corners shall be maintained by surveyor.
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12.3
Survey records must contain schematic diagrams of all horizontal controls pertinent
to the project showing all existing and established control points, bench marks, any
triangulation station and boundary lines.
12.4
Geo-graphical and UTM co-ordinates of all Turning Points and starting / end points
of the pipeline shall be computed and furnished to the COMPANY / ENGINEER.
13.0 MAPS AND DRAWINGS:

13.1
All maps and drawings shall be made on standard format furnished by the
COMPANY. Surveyor shall perform mapping and drawing work so as to contain all
relevant data consistent with the survey notes and observations. The drawings
shall also contain details of roads, streets, highways, structures, all types of
crossings, terrain, surface vegetation and all other details which will be required for
the purpose of engineering design.
13.2
Following types of detailed survey drawings will be made.
Right-of-Use Planimetry in UTM grid
1:5000 along the line

1:1000 across the line
Ground Profile
1:5000 Horizontal
1:500 Vertical
Crossing Details (Road & Railway

Crossings)
1:100 Horizontal
1:100 Vertical
Crossing details (River / Stream /

Nala / Canal Crossings)
1:100 Horizontal
1:100 Vertical
Detailed Route Map
1:50,000
Additional Route Map for Hilly, Ghat

and ravenous regions
1:15,000
Cross Section for sloping Right-of-Use
1:100 Horizontal
1:100 Vertical
14.0 PRESENTATION OF FIELD SURVEY DATA:

Survey drawings shall contain the following data as a minimum requirement.
14.1
Pipeline Route Map

Pipeline route map shall show all features including, but not limited to roads and
railroads, canals, streams, lakes, rivers, villages, towns, and cities that are located
within a distance of 5 Krn from the pipeline centre-line on either side of it. For the
entire region, contours shall be plotted on the route map at 20 M contour interval.
Additional information like cultivated areas, barren land, areas prone to flooding,
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rocky areas and forests including access paths / roads to Right-of-Use shall also be
shown on the route maps.
Additionally for areas which are undulating such as hilly areas, Ghat regions,
ravines, and other areas as directed by COMPANY, Pipeline route map to a scale 1:
15,000 shall be drawn over a distance of 1.0 Km from the pipeline centre-line on
either side of it. For such areas, contours shall be plotted at 10m contour interval.
14.2
Right-of-Use Planimetry drawings shall show all objects within 50 meters on either
side of the Pipeline in Plan.
14.3
In case of all rail, road, river, stream, canal and utility crossings, the angle of
crossing shall be mentioned.
14.4
In case or rail, road, river, stream and canal crossings wider than 10m, the
distances at the start and at the end of the crossing from the nearest IP shall also
be mentioned. For crossings less than 10m, the distance of the centre line of
crossing from the nearest IP shall be given.
14.5
For all river, stream and nalla crossings, the level of water at the time of survey
and the approximate surface velocity of the flowing stream shall be observed and
recorded and reported in the survey drawings. Also, the general nature of the
surface soil (soft / hard, normal soil or rock/boulders) at the bed and banks of the
river / stream / nalla shall be observed and mentioned in the drawings.
15.0 DOCUMENTS / DATA SUBMISSION:

All drawings, reports, formats etc. submitted to COMPANY shall be prepared on
electronic media. All drawings shall be prepared using Autocad Release 12/13 (or
later version) software operating under Disk Operating System (DOS) environment.
The documents shall be prepared using Word Perfect / Microsoft Word / lotus
softwares.
In addition, hard copies of documents shall also be submitted.
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ANNEXURE - I
SPECIFICATION FOR SOIL INVESTIGATION
1.0
GENERAL:
The purpose of soil investigation is to be obtain visual engineering classification of
soil along the pipeline route.
2.0
SCOPE:
The scope of soil investigation includes boring, collection of disturbed samples from
boreholes and visual engineering classification of soil along the pipeline route, and
submission of detailed report to COMPANY. Visual classification of soil shall be in
accordance with IS-1498; "IS Classification and Identification of Soils for General
Engineering Purposes".
3.0
BORING:
3.1
Boreholes shall be made at intervals of 500 M along the pipeline route, at all
intermediate points where there is apparently a change in the type of soil and at
any other place as directed by COMPANY.
3.2
For canal, stream and river crossings, boreholes shall be made one on either bank
and one on the bed.
3.3
Minimum diameter of borehole shall be 150 MM. Auger boring shall be resorted to
above the water table, whereas below water table the boreholes shall be advanced
by shell and auger.
3.4
The boring shall be either terminated at a depth of 3 M below NGL or on top of

bed rock if rock is encountered at a depth of less than 3 M.
4.0
SAMPLING:
Disturbed representative samples shall be collected from boreholes to classify the
subsoil visually at site.
5.0
DETAILED REPORT:
5.1
The report shall include proper visual engineering classification of soils

encountered along the pipeline route in bore log form. Depth of Ground Water
Table (GWT) below NGL shall also be mentioned if encountered.
5.2
Soil profiles along the pipeline route shall also be prepared and attached with the
report.
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5.3
Regions along the pipeline route where special excavation techniques like blasting,
etc. needs to be adopted for excavation of pipeline trenches shall be clearly
indicated in the report.
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ANNEXURE-II
ADDITIONAL REQUIREMENT FOR GAS PIPELINES DETERMINATION OF
POPULATION DENSITY INDEX AND CLASS LOCATION
1.0
When survey is performed for gas pipelines, the class locations based on
population density index as per code ANSI B3l.8 "Gas Transmission and
Distribution Piping Systems" shall be recorded along with chainages at change
points of each class location.
2.0
Population density index along the pipeline route shall be determined as follows:
As zone, 400 M (one quarter mile) wide, shall be considered along the pipeline
route with the pipeline in the centre-line of this zone. Then the entire route of the
pipeline shall be divided into lengths of 1600 M (one mile) such that the individual
lengths will include the maximum number of dwellings intended for human
occupancy. The number of such dwellings which are intended of human occupancy
within each 1600 M (one mile) zone shall be counted and reported along with
other survey data.
3.0
Areas shall be classified based on guidelines as given below:
3.1
Class 1 Location
A Class 1 location is any 1600 M (one mile) section that has 10 or fewer dwellings
intended for human occupancy
Class 2 Location
A Class 2 Location is any 1600 M (one mile) section that has more than 10 but less
than 46 dwellings intended for human occupancy.
Class 3 Location
A Class 3 Location is any 1600 M (one mile) section that has 46 or more dwellings
intended for human occupancy except when a Class 4 Location prevails.
Class 4 Location
3.2
A class 4 Location includes areas where multi-storey buildings are prevalent, and
where traffic is heavy or dense and where there may be numerous other utilities
under ground.
In addition to the criteria contained in Clause 3.1 above, while classifying areas,
additional consideration must be given to possibilities of increase in concentration
of population along the pipeline route such as may be caused by the presence of
schools, hospitals, recreational areas of an organized character, places of
assembly, places of worship, etc. If one or more of these facilities are present, the
area shall be classified as a Class 3 Location.
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3.3
Notwithstanding the provisions of Clause 3.1 and 3.2 above, while determining
class location of an area due consideration shall be given to the possibility of future
development of the area during the design life of the pipeline. If it appears likely
that future development may cause a change in the location class, this shall be
taken into consideration while determining its class location.
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ANNEXURE-III
ADDITIONAL REQUIREMENT FOR HIGH VAPOUR PRESSURE (HVP)
LIQUID PETROLEUM PIPELINES - ZONE LOCATION
1.0
When survey is performed for High Vapour pressure (HVP) liquid petroleum
pipelines, zone location shall be recorded along the pipeline route along with
chainages at change points of each zone location. (For definitions refer Oil Industry
Safety Directorate (OISD) Standard 141 Design and Construction Requirements by
Cross Country Hydrocarbon Pipelines)
2.0
A zone, 200M wide on either side of the centre-line of the pipeline route, shall be
considered. Then the entire route of the pipeline shall be divided into lengths of 1
Km such that the individual lengths will include the maximum number of dwellings
intended for human occupancy within each 1 Km zone shall be counted and
reported along with other survey data.
3.0
Zone locations shall be determined as follows:
3.1
A zone 1 Location is an area extending 200 meters on either side of the centre-line
of any continuous 1 KM length of pipeline that contains 5 or fewer dwelling units
intended for human occupancy.
3.2
A Zone 2 Location is an area as defined in clause 3.1 above that contains more
than 5 dwelling units intended for human occupancy, or a facility that contains 20
or more persons during normal use.
3.3
Each dwelling unit in a multiple dwelling unit building shall be counted as a

separate unit.
3.4
When a facility creates Zone-2 location requirements, the Zone 2 area shall extend
at least 200 meters from that facility.
4.0
Notwithstanding the provisions of clause 3.0 above, while determining zone

location of an area due consideration shall be given to the possibility of future
development of the area during the design life of the pipeline. If it appears likely
that future development may cause a change in the zone location, this shall be
taken into consideration while determining the zone location of the area.
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ANNEXURE-IV
PIPELINE ROUTE SURVEY DATA SHEET
Pipeline size
MM OD
Gradient (ROU)
(max) Along pipeline alignment
Bend radius
Minimum distance between TPs
Maximum deflection angle at TPs
Permissible variation in pipeline length
ROU width to be acquired
Pipeline location in the ROU
Minimum distance from existing

Buildings / structures / monuments
Co-ordinates of starting point
Habitable dwellings
Structures
Property corners / monuments
To be established by Contractor
Note: Number of TPs / Bends in the pipeline, whether in horizontal or in vertical direction
shall be kept to a minimum
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FABRICATION OF PIPING
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CONTENTS
--
1.0
GENERAL
2.0
APPLICABLE CODES & STANDARDS
3.0
BASE MATERIALS
4.0
WELDING CONSUMABLES
5.0
SHIELDING & PURGING GAS
6.0
EQUIPMENTS & ACCESSORIES
7.0
WELDING PROCESSES
8.0
EDGE PREPARATION
9.0
ALIGNMENT & SPACING
10.0
WEATHER CONDITIONS
11.0
WELDING TECHNIQUE
12.0
HEAT TREATMENT
13.0
CLEANING OF THE WELD JOINT
14.0
15.0
REPAIRS OF WELDS
16.0
DOCUMENTS TO BE SUBMITTED BY CONTRACTOR

FORMATS
EXHIBIT A
TO
EXHIBIT H
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(This specification shall be used in conjunction with Welding Specification Charts).

1.0
GENERAL:
This specification shall be followed for the fabrication of all types to welded joints
of piping system within the battery limits of the plant.
The welded pipe joints shall include the following:
a)
b)
All pipe joints, longitudinal butt welds, circumferential butt welds and socket
welds.
Attachments of forgings, flanges and other supports to pipes.
c)
Welded manifold headers and other sub-assemblies.
d)
Welded branch connections with or without reinforcing pads.
e)
Joints in welded/fabricated piping components.
f)
The attachments of smaller connections for vents, drain drips and other
instrument tapings.
Any approval granted by the Engineer-in-Charge or Owner's inspector, shall not

relieve the Contractor of his responsibilities and guarantee.
This specification shall not be applicable for welding of pipelines for transportation
of liquid petroleum and other similar products.
2.0
APPLICABLE CODES & STANDARDS:

All welding work, equipments for welding, heat treatment, other auxiliary functions
and the welding personnel shall meet the requirements of the latest editions of the
following accepted standards and procedures unless otherwise specified in the
Welding Specification Chart and the Technical notes attached thereof. In the case
of conflicting requirements, the requirements mentioned in welding Specification
Chart/Technical Notes shall be applicable.
i)
ASME Code for Pressure Piping - ASME B31.3
ii)
ASME Boiler & Pressure Vessel Code, Sec II Part C, Material Specifications:
Welding Rods, Electrodes and Filler metals.
iii)
ASME Boiler & Pressure Vessel Code, Section V, Non destructive

examination.
iv)
ASME Boiler & Pressure Vessel Code, Section VIII, Rules for Construction of
Pressure Vessels.
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v)
ASME Boiler & Pressure Vessel Code, Section IX, Welding and Brazing
Qualifications.
vi)
The Indian Boiler Regulations -
IBR
In the event of any differences due to the additional requirements mentioned in

this specification, over and above those obligatory as per codes, this specification
shall be binding.
3.0
BASE METAL:
3.1
In general, use of carbon steel, alloy steel and stainless steel is envisaged. The
details of the material specifications are given in the Welding Specification Chart.
3.2
The Contractor shall provide the manufacturer's test certificates for every heat of
the materials supplied by him.
4.0
WELDING CONSUMABLES:
4.1
The Contractor shall provide, at his own expense, all the welding consumables
necessary for the execution of the job such as electrodes, filler wires, argon etc.
and these should bear the approval of the Engineer-in-Charge.
4.2
The welding electrodes and filler wires supplied by the Contractor shall conform to
the class specified in the Welding Specification Chart. The materials shall be of the
make approved by the Engineer-in-Charge.
4.3
Electrode qualification test records should be submitted as per the Exhibit-A

(attached) in respect of the electrodes tested by the Contractor, for obtaining the
approval of the Engineer-in-Charge.
4.4
The Contractor shall submit batch test certificates, from the electrode
manufacturers, giving details of physical and chemical tests carried out by them,
for each batch of electrodes to be used.
4.5
All electrodes shall be purchased in sealed containers and stored properly to

prevent deterioration. The electrodes removed from the containers shall be kept in
holding ovens at temperatures recommended by the electrode manufacturer. "Out
of the oven time" or electrodes, before they are consumed, shall not exceed the
limits recommended by the electrode manufacturer. The electrodes shall be
handled with care to avoid any damage to the flux covering.
4.6
All low hydrogen type of electrodes shall be rebaked at 350C for 1 hour minimum
and stored in ovens kept at 80-100C before use. Recommendations of the
electrode manufacturer shall I be followed if available.
4.7
The electrodes, filler wires and flux used shall be free from rust, oil, grease. earth
and other foreign matter which affect the quality of welding.
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4.8
Tungsten electrodes used shall conform to ASME Sec. II C SFA 5.12 specification.
5.0
SHIELDING & PURGING GAS:
5.1
Argon gas used in GTA welding for shielding purposes shall be 99.995% pure. The
purity of the gas shall be certified by the manufacturer. The rate of flow for
shielding purposes shall be established through procedure qualification tests.
Normally this rate may be 12-20 CFH.
5.2
Argon gas with a purity level of 99.995% shall be used for purging.
5.3
When GTAW process alone or a combination of GTAW and SMAW processes is

recommended for the production of a particular joint, the purging shall be
maintained during the root pass and for the first filling pass to minimize oxidation
on the inner side of the pipe, unless otherwise specified in Welding Specification
Chart.
5.4
Initial purging shall be maintained for sufficient period of time so that at least 4-5
times the volume between the dams is displaced, in order to completely remove
the entrapped air. In no case should the initial purging period be less than 10
minutes. High gas pressure should be avoided.
5.5
After initial purging, the flow of the backing gas should be reduced to a point
where only a slight positive pressure prevails. For systems, which have a small
volume (up to cubic foot) to be purged, a gas flow rate of 6-CFH is usually
adequate. Systems of larger volume may require higher flow rates and these
should be established during procedure qualification tests.
5.6
Gas backing (purging) is not required for socket type of welded joints.
5.7
Dams, used for conserving inert gas during purging, shall be removed after
completion of the welding, and shall be accounted for. Wherever, removal of dams
is not possible after welding, use of water-soluble dams should be made.
6.0
EQUIPMENTS & ACCESSORIES:
6.1
The Contractor should have the arrangement of sufficient number of welding and
cutting equipments, auxiliaries, and accessories of sufficient capacities so as to
meet the target / schedule.
6.2
All the equipments for performing the heat treatment, including transformers,
thermocouples, pyro-meters, automatic temperature recorders (with suitable
calibration arrangement etc.) shall be provided by the Contractor at his own
expenses and these should bear the approval of the Engineer-in-Charge.
6.3
Contractor shall make necessary arrangements at his own expense, for providing
the radiographic equipments, radiographic films, processing equipment all other
darkroom facilities and all the equipments/materials required for cawing out the
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dye penetrant / magnetic particle test/ultrasonic testing for satisfactory and timely
completion of the job.
6.4
Redoing of any work, necessitated by faulty equipments or operation used by the

Contractor, will be done at his own expense.
7.0
WELDING PROCEDURE:
7.1
Welding of various materials under this specification shall be carried out using one
or more of the processes with the approval of the Engineer-in-Charge.
-
Shielded Metal Arc Welding Process (SMAW).
Gas Tungsten Arc Welding Process (GTAW)
7.2
The welding processes to be employed are given in the Welding Specification

Chart. Any deviation desired by the Contractor shall be obtained through the
express consent of the Engineer-in-Charge.
7.3
Automatic and semi-automatic welding processes shall be employed only with the
express approval of the Engineer-in-Charge. The welding procedure adopted and
consumables used shall be specifically approved.
7.4
A combination of different welding processes 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.
8.0
EDGE PREPARATION:
8.1
General
The edges to be welded shall be prepared to meet the joint design requirements
by any of the following methods recommended:
(a)
Carbon Steel
Gas cutting, machining or grinding methods shall be used. After gas cutting,
oxides shall be removed by chipping or grinding.
(b)
Low Alloy Steels (containing up to 5% Chromium).

Gas cutting, machining or grinding methods shall be used. After gas cutting,
machining or grinding shall be carried out on the cut surface.
(c0
High alloy steel (> 5% Chromium) and stainless steels, nickel alloys:
Plasma cutting, machining or grinding methods shall be used. After plasma
cutting, cut surfaces shall be machined or ground smooth.
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8.2
Cleaning
(a)
The ends to be welded shall be properly cleaned to remove paint, oil,

grease, rust, oxides, sand, earth and other foreign matter. The ends shall be
completely dry before the welding commences.
(b)
On completion of each run, craters, welding irregularities, slag etc., shall be

removed by grinding and chiseling. Wire brushes used for cleaning stainless
steel joints shall have stainless steel wires and the grinding wheels used for
grinding stainless steel shall be of a suitable type. Separate grinding wheels
and wire brushes should be used for carbon steels and stainless steels.
9.0
ALIGNMENT & SPACING:
9.1
Components to be welded shall be aligned and spaced as per the requirements laid
down in applicable code. Special care must be taken to ensure proper fitting and
alignment when the welding is performed by GTAW process. Flame heating for
adjustment and correction of ends is not permitted unless specifically approved by
the Engineer-in-Charge.
9.2
A wire spacer of suitable diameter may be used for maintaining the weld root
opening while tacking, but it must be removed after tack welding and before laying
the root bead.
9.3
For pipes of wall thickness 5 mm and above, the ends to be welded shall be
secured in position with the aid of couplers, yokes and 'C' clamps, to maintain
perfect alignment. Yokes shall be detached after the completion of weld, without
causing any surface irregularity. Any irregularity caused on the pipe surface must
be suitably repaired to the satisfaction of the Engineer-in-Charge.
9.4
Tack welds, for maintaining the alignment, of pipe joints shall be made only by
qualified welders using approved W S . Since the tack welds become part of the
final weldment they shall be executed carefully and shall be free from defects.
Defective tack welds must be removed prior to the actual welding of the joints.
9.5
Tacks should be equally spaced. Minimum number of tacks shall be:
9.6
3 tacks
for 2 1/2" and smaller dia. pipes
4 tacks
for 3" to 12" dia. pipes
6 tacks
for 14" and larger dia. pipes
Welding shall commence only after approval of fit-up by the Engineer-In-Charge.
10.0 WEATHER CONDITIONS:
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10.1
10.2
The parts being welded and the welding personnel should be adequately protected
from rain and strong winds. In the absence of such a protection no welding shall
be carried out.
During field welding using GTAW process, particular care shall be exercised to
prevent any air current affecting the welding process.
11.0 WELDING TECHNIQUE:

11.1
Root Pass
(a)
Root pass shall be made with electrodes/filler wires recommended in the

welding specification chart. For fillet welding, root welding shall be done
with consumables recommended for filler passes. The preferred size of the
electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than
3.25 mm (10 SWG).
(b)
Upward technique shall be adopted for welding pipe held fixed with its
axis horizontal.
(c)
The root pass of butt joints should be executed so as to achieve full

penetration with complete fusion of the root edges. Weld projection
inside the pipe shall be as per applicable code. It shall be limited 3mm
map, when the applicable code does not place any restriction.
(d)
Any deviation desired from the recommended welding technique and

electrodes indicated in the welding specification chart should be adopted
only after obtaining express approval of the Engineer-in-Charge.
(e)
Welding shall be uninterrupted.
(f)
While the welding is in progress care should be taken to avoid any kind
of movement of the components, shocks, vibrations and stresses to
prevent occurrence of weld cracks.
11.2 Joint Completion

(a)
Joint shall be completed using the class of electrodes, recommended in

the Welding Specification Chart. Size of the electrode shall not exceed 4
mm in diameter for stainless steels and alloy steels used for low
temperature applications.
(b)
(c)
Two weld beads shall not be started at the same point in different layers.
Butt joints shall be completed with a cover layer that would affect good
fusion at the joint edges and a gradual notch free surface.
(d)
Each weld joint shall have a workmanship like finish. Weld identification
work shall be stamped clearly at each joint, just adjacent to the weld.
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Metal stamping shall not be used on thin pipe having wall thickness less
than 3.5mm. Suitable paint shall be used on thin wall pipes for
identification.
(e)
Rust preventive / protective painting shall be done after the weld joint
has been approved.
11.3 Dissimilar Welds

Where welds are to be produced between carbon steels and alloy steels,
preheat and post weld heat treatment requirements shall be those specified for
corresponding alloy steels and filler wire / electrodes shall correspond to ER 70
S-G or AWS E-7016/7018 type. For welds
between two dissimilar Cr-Mo low alloy steels, preheat and post weld heat
treatments shall be those specified for higher alloy steel and electrodes used
shall correspond to those specified for steel of lower alloy content. For carbon
steel or alloy steel to stainless welds, use of filler wire / electrodes E / ER-309 /
E-310 / E NiCr Fe-3 shall be made. The welding procedure, electrodes / filler
wires to be used shall be approved by the Engineer-in-Charge.
12.0 HEAT TREATMENT:
12.1 Preheating
(a)
No welding shall be performed without preheating the joint to 10C (50F)

when the ambient temperature is below 10C.
(b)
Preheating requirements for the various materials shall be as per the

Welding Specification Chart attached.
(c)
Preheating shall be performed using resistance or induction heating

methods. Preheating by gas burners, utilizing oxy-acetylene or oxy-propane
gas mixtures, with neutral flame may also be carried when permitted by the
Engineer-in-Charge
(d)
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.
(e)
Preheating temperature shall be maintained over the whole length of the

joint during welding. Temperature recorders shall be provided by the
Contractor to record the temperature.
12.2 Post Heating

In case of alloy steel materials such as Cr-Mo steels, if the post weld heat
treatment is not performed immediately after welding, the weld joint and adjacent
portion of pipe, at least 50 mm on either side of weld, shall be uniformly heated to
300C. This temperature shall be maintained for half an hour minimum, and then
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wrapped in asbestos or insulation before allowing it to cool to room temperature. If

the Post Heating temperature specified in the Welding Specification Charts exceeds
300C, the same shall be followed. Similarly, if the welding specification chart
specifies post-heat time, the same shall be applicable. Post weld heat treatment as
specified in the Welding Specification Chart shall be carried out later on.
12.3 Post Weld Heat Treatment

(a)
Post weld heat treatment, wherever required for joints between pipes, pipes
and fittings, pipe body and supports shall be carried out as per the welding
specification chart, applicable codes standards and the instructions of the
Engineer-in-Charge.
(b)
The Contractor shall submit for the approval of the Engineer-in-Charge, well
before carrying out actual heat treatment, the details of the post weld heat
treatment procedure as per Exhibit - B attached, that he proposes to adopt
for each of the materials / assembly /parts involved.
(c)
Post weld heat treatment shall be done in a furnace or by using an

electronic resistance or induction-heating equipment, as decided by the
Engineer-in-Charge.
(d)
While caving out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the
portion being heat treated. Care shall be taken to ensure that width of
heated band over which specified post weld heat treatment temperature
attained is at least that specified in relevant applicable codes /standards.
Throughout the cycle of heat treatment, the portion outside the heated
band shall be suitably wrapped under insulation so as to avoid any harmful
temperature gradient at the exposed surface of pipe. For this purpose
temperature at the exposed surface should not be allowed to exceed 50%
of the peak temperature.
(e)
(f)
The temperature attained by the portion under heat treatment shall be

recorded by means of thermocouple pyrometers. Adequate number of
thermocouples should be attached to the pipe directly at equally spaced
location along the periphery of the pipe joint. The minimum number of
thermocouples attached per joint shall be 1 up to 6" dia., 2 up to 10" dia.
and 3 for 12" dia. and above. However, the Engineer-in- Charge can
increase the required number of thermocouples to be attached if found
necessary.
(g)
Automatic temperature recorders, which have been suitably calibrated,

should be employed for measuring & recording the temp. The time-temp
graph shall be submitted to Engineer-in-Charge immediately on completion
of S.R. The calibration chart of each recorder should be submitted to the
Engineer-in-Charge prior to starting the heat treatment operations and his
approval should be obtained.
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(h)
Manufacturer's test certificate shall be submitted for the thermocouple

materials.
(i)
Immediately on completion of the Heat Treatment, the Post Weld Heat

Treatment charts/records along with the hardness test results on the weld
points, wherever required as per the Welding Specification Chart, shall be
submitted to Engineer-in-Charge for his approval.
(j)
Each joint shall bear an identification number, which shall be maintained in

the piping sketch to be prepared by the Contractor. The joint identification
number should appear on the corresponding post weld heat treatment
charts. The chart containing the identification numbers and piping sketch
shall be submitted to Engineer-in-Charge in suitable folders.
13.0 CLEANING OF THE WELD JOINTS:

All weld joints shall be free from adherent weld spatters slag, sward, dirt or foreign
matter. This can be achieved by brushing. For stainless steels, brushes with only
stainless steel bristles should be used.
14.0 INSPECTION AND TESTING:
14.1 General
(a)
The Owner's inspector shall have free access to all concerned areas, where
the actual work is being performed. The contractor shall also accord the
Owner's Inspector all means and facilities necessary to carry out inspection.
(b)
The Owner is entitled to depute his own inspector to the shop or field where
prefabrication and erection of pipe lines is in progress for (but not limited
to) the following objectives:
(c)
i)
To check the conformance to relevant standards and suitability of

various welding equipments and the welding performance.
ii)
To witness the welding procedure qualification.
iii)
To witness the welder performance qualification.
iv)
To check whether shop / field welding being executed is in

conformity with the relevant specifications and codes of practice
followed in piping construction.
Contractor shall intimate sufficiently in advance the commencement of

qualification tests, welding works and acceptance tests, to enable the
Owner's inspector to be present to supervise them.
14.2 Welding Procedure Qualification
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Welding procedure qualification shall be carried out in accordance with the relevant
requirements of ASME Sec. IX latest edition or other applicable codes and the job
requirements. The contractor shall submit the welding procedure specification in
format as per Exhibit-C (attached) immediately after the receipt of the order.
Owner's inspector will review, check and approve the welding procedure submitted
and shall release the procedure for qualification tests. The procedure qualification
test shall be carried out by the Contractor at his own expense. A complete set of
test results in the format as per Exhibit-D (attached) shall be submitted to the
Owner's inspector for his approval immediately after completing the procedure
qualification test and at least 2 weeks before the commencement of actual work.
Standard test as specified in the code shall be carried out in all cases. In addition
to these tests, other tests like macro/micro examination, hardness tests. Dye
penetrant examination, charpy V-notch, Corrosion tests, impact tests etc. shall be
carried out on specimens depending upon the type of base material, operating
conditions and requirements laid own in the detailed drawings and specifications. It
shall be the responsibility of the Contractor to carry out all the tests required to the
satisfaction of the Owner's inspector.
14.3 Welder's Qualification

(a)
Welders shall be qualified in accordance with the ASME Section-IX or other

applicable codes. The Owners inspector shall witness the test and certify the
qualification of each welder separately. Only those welders who have been
approved by the Owner's Inspector shall be employed for welding.
Contractor shall submit the welder qualification test reports in the format as
per Exhibit-E (attached) and obtain express approval before commencement
of work. It shall be the responsibility of Contractor to carry out qualification
tests of welders. For welding of the steam piping, falling under the purview
of Indian Boiler Regulations only those welders with IBR Certification,
qualified by Boiler Inspectorate, and acceptable to the local Boiler Inspector
authority shall be employed.
(b)
The welders shall always have in their possession the identification card as
shown in Exhibit4 and shall produce it on demand by the Owner's inspector.
It shall be the responsibility of the Contractor to issue the identify cards
after it has been duly certified by the Inspector.
(c)
No welder shall be permitted to work without the possession of identify

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
14.4 Visual Inspection
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Inspection of all welds shall be carried out 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 of
welds, shrinkage cracks, inadequate penetration, unrepaired burn-through, under
cuts, dimensions of the weld,
Surface porosity and other surface defects. Undercutting adjacent to the completed
weld shall not exceed the limits specified in the applicable standard / code.
14.5 Radiographic Examination

(a)
Contractor shall appoint agency for carrying out the radiography works at
site from the list of agency (ies) enclosed in the bid document or separately
supplied by owner.
(b)
The Radiographic Examination procedures to be adopted shall be submitted

by the contractor as per Exhibit-F and shall be got approved from the
Owner's Inspector prior to employment. A person qualified to ASNT Level-II
in Radiographic testing shall prepare the procedure. The Radiography
Procedure shall be established to demonstrate that the required sensitivity
can be consistently achieved under the most unfavorable parameters (e.g.
source to film distance, geometric unsharpness, thickness etc.). The
radiographic technique and procedure adopted shall conform of the
requirements mentioned in Article 2 as well as Article 22 (SE 94, 142, 747,
999 & 1025) of ASME Sec.V. The IQI sensitivity obtained shall be equal to
or better than the requirements mentioned in Article 2 of ASME Sec. V.
Source side penetrameter shall be used in establishing radiographic
procedure/ technique. The acceptance criteria shall be as per the relevant
codes of Fabrication and over riding requirements if mentioned else where
in the technical specifications of the contract. The Contractor shall be
responsible for carrying out Radiography; rectification of defects and reradiography of welds repaired / rectified at his cost.
(c)
The extent of Radiography shall be as per specifications to be supplied to

the Contractor. For welds between dissimilar materials, the extent of
Radiographic Examination shall be the more stringent of the two
recommended for the materials being welded. Wherever random
Radiography is called for, in a particular piping class, the dissimilar materials
weld joints shall essentially be included.
(d)
Type of Radiation source and film to be used shall be as per Exhibit-H for
carrying out radiographic examination. However if specifications (as given
else where in the contract) for some critical material require usage of XRadiation, then Radiography shall be done using X-Rays only.
(e)
The Contractor shall fulfill all the statutory and owner's safety requirements
while Handling X-ray and Gamma-ray equipments.
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(f)
The joints for Radiography shall be selected by the Owner's Inspector and
the Radiography shall be performed in his presence, if he instructs the
contractor to do so. The contractor shall furnish all the radiographs, to the
Owner's inspector immediately after processing along with evaluation by a
person qualified to ASNT Level - II in Radiographic testing, inline with clause
T-292 of Article 2 of ASME Sec. V. The certificate of ASNT Level-II (RT)
personnel shall be submitted to owner's inspector for his approval prior to
start of job.
(g)
The Contractor shall provide the Owner's Inspector all the necessary
facilities at site such as a dark room with controlled temperature, illuminator
(viewer) suitable for varying densities, a duly calibrated electronic
densitometer with batteries, magnifying glass, tracing papers, ruler marking
pencils etc. to enable him to review the radiographs.
(h)
Where random radiography is specified, the first weld of each welder shall
be completely radiographed. In the case of pipe of size 6" and below, the
first two welds shall be completely radiographed.
(i)
For each weld performed by a welder found unacceptable, two additional

checks shall be carried out on welds performed by the same welder. This
operation is iterative and of the two additional welds for each weld deemed
unsatisfactory shall be continued till such time that two consecutive welds of
satisfactory quality are found for every defective weld.
(j)
The Contractor shall carry out these additional radiographic testing at his
own expense. To avoid the possibility of too many defective welds by a
single welder remaining undetected for a long period to time, the Contractor
shall promptly arrange for Radiographic Examination so that there is no
accumulation of defective joints.
(k)
Contractor shall quote rates for X-ray as well as Gamma Ray for joints
indicated to be radiographed by X-ray in Table of Exhibit-H.
14.5.1
14.6
Check Shots
(a)
Owner shall select 5% of the total joints radiographed on a day for check
shots. Contractor shall carry out check shots as directed.
(b)
Weld profiles of check shots shall be compared with weld profile observed in
the earlier Radiographs. In the event of any one variation in the check shots
and earlier Radiographs, contractor shall re-shoot the entire lot of joints
radiographed by particular Radiography agency on the particular date. All
the re-shot films shall be compared with the originally submitted films.
Liquid Penetrant and Magnetic Particle Examination
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14.7
(a)
Whenever such tests are specified, the tests shall be carried out on joints
chosen by the Owner's inspector, as per ASME Section V article 6 and 7
respectively.
(b)
For austenitic stainless steels and other nonmagnetic materials, liquid (dye)
penetrant test shall be carried out. For carrying out this test, the materials
shall be brought within a temperature limit of 15 - 500C.
Hardness Test
Hardness requirements for welds shall be as per the Welding Specification Chart
(attached). Hardness testing shall be carried out by Vickers Hardness Tester during
welding procedure qualification and shall be cross sectional. In all other cases,
hardness testing may be carried out by Portable Shore Seleroscope hardness
tester. Contractor shall produce documentary evidence / calibration certificate to
the Owner's Inspector and obtain approval of the equipment.
14.8
Proof Tests
Hydrostatic and pneumatic tests shall be performed as per the requirements laid
down by respective flushing and Testing specification/applicable codes to
demonstrate the soundness of the welds. The tests shall be conducted after
fulfilling the requirement of visual examinations, radiography etc. and after the
entire work has been certified by the Owner's inspector to be fit for being
subjected to such tests.
15.0
16.0
REPAIRS OF WELDS:
(a)
Defects ascertained, through the inspection methods, which are beyond

acceptable limits shall be removed after the joint is completely radiographed
by the process of chipping and grinding.
(b)
When the entire joint is judged unacceptable, the welding shall be

completely cut and edges suitably prepare as per required alignment
tolerances. The re-welded joint shall again be examined following standard
practices.
(c)
No repair shall be carried out without prior permission of the Owner's

inspector.
(d)
Repairs and / or work of defective welds shall be done in time to avoid

difficulties in meeting the construction schedules.
DOCUMENTS TO BE SUBMITTED BY CONTRACTOR (4 COPIES EACH):

(a)
Electrode and Welding Consumable Qualification Records as per Exhibit-A,

for the Welding Consumables tested and approved for the work.
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(b)
Batch Test Certificates, for the Electrodes used, obtained from the Electrode
Manufacturers.
(c)
Proposed Heat Treatment Procedure as per Exhibit-B .
(d)
Heat Treatment Charts.
(e)
Weld joint hardness test results.
(f)
Welding Procedure Specifications as per Exhibit-C immediately after receipt

of the order.
(g)
Welding Procedure Qualification records as per Exhibit-D.
(h)
Welder Performance Qualification records as per Exhibit-E immediately after

conducting Welder Qualification Tests.
(i)
Radiography Procedure as per Exhibit-F and other NDT procedures.
(j)
Radiographic test Report along with Radiographs and other NDT reports.
(k)
Piping Sketch (Isometric) giving all the details regarding the pipe
specifications, welded joints, joints radiographed magnetic particle, tested,
ultrasonic tested, penetrant tested, joints heat treated, WPS used, welders
identification number, etc.
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EXHIBIT - A
Sheet 1 of 3
ELECTRODE QUALIFICATION TEST RECORD
A:
B:
Tested at (Site name)
Date:
Manufacturer's 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
Identification No.
GAIL (INDIA) LTD

NEW DELHI
U.T.S
Yield Point
Elongation

Remarks
DOCUMENT NO.
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Page 17 of 32
EXHIBIT - A
Sheet 2 of 3
C:
Impact Test Results

Test Temperature:
Notch in:
Type of Specimens (Charpy):

Specimen No.
Size of Specimens:
Impact Value
Average
1
2
3
D:
Chemical Analysis Results
%C
E:
Electrode Size Result
Batch No.
%S
%P
% Si
% Mn
Fillet Weld Test Results
Welding Positions
Base Materials
Size of electrode use
Visual Inspection Results
% Cr
% Ni
% Mo
OTHER
1)
2)
3)
GAIL (INDIA) LTD

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DOCUMENT NO.
S-04-02-034
REV-0
Page 18 of 32
EXHIBIT - A
Sheet 3 of 3
F:
Macro Test Results
Fracture Test Results
Remarks
Other Test Results

1.
Transverse tensile test
In combination with
Base material used
Position of welding
Preheat temperature
Post weld heat treatment
Radiography
Identification No.
2.
Guided Bend Test
POSITION
IDENTIFICATION
NO.
1
2
3
U.T.S
Fracture in
:
ROOT, FACE OR
SIDE BEND
G.
Any other tests
H.
Conclusions
--------------PREPARED BY
(CONTRACTOR)
GAIL (INDIA) LTD

NEW DELHI
Remarks
----------------REVIEWED BY
(CONTRACTOR)

REMARKS
---------------APPROVED BY
(OWNER)
DOCUMENT NO.
S-04-02-034
REV-0
Page 19 of 32
EXHIBIT B
Sheet 1 of 2
STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
Contractor : _____________________________________________________
Name of the Heat treater
:
__________________________________________
Name of the Project
:_____________ Specification:_______
Reference No. _______
________________________________________________________
1.
General Details
Other Details
Name of the
equipment:________
Type of heating: Elec. Res /

Induction
(Tick mark applicable method)
Maximum Permissible Temp at
Uncovered Parent Metal_____
Width of heated Band_______
Width of Insulation_________
Material:___________________
No. of Thermo Couples (dia wise)

__________________
Type of Thermo Couples___________
2.
Heat Treatment Cycle Details

Charging Temp
(0C) __________________________________
Rate of heating
(0C/Hr.)_______________________________
Soaking Temperature (0C)_______________________________
GAIL (INDIA) LTD

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DOCUMENT NO.
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REV-0
Page 20 of 32
EXHIBIT B
Sheet 2 of 2
Soaking Time (Hrs.) ___________________________________
Rate of cooling
(0C/Hr.)_______________________________
Method of Cooling_____________________________________
3.
Other Details, if any ___________________________________

___________________________________________________
___________________________________________________
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-04-02-034
REV-0
Page 21 of 32
EXHIBIT C
Sheet 1 of 3
FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
Company Name ________________________ BY___________________
Welding Procedure Specification No.________ Date _________________
Supporting PQR No. (S)________________ Revision No. ____ Date_____
Welding Process (es)___________________ Type (s) _______________
(Automatic, Manual, Machines or
Semi Auto)
JOINTS
Joint Design ________________________________________________
Backing (Yes)____________________________ (No)_______________
Backing Material (Type)_______________________________________
Sketches Production Drawings. Weld Symbols Written________________
Description shod show the general arrangement of the parts to be welded. Where
applicable, the root spacing and the details of weld groove may be specified
___________________________________________________
(At the option of the Manufacturer sketches may be attached to illustrate joint
design weld layers and bead sequence e.g. for notch toughness procedures, for
multiple process procedures, etc.)
BASE METALS
P No. _______ Group No. ________ to P. No. ______ Group No._______
OR
Specification type and grade ____________________________________
to Specification type and grade__________________________________
OR
Chem. Analysis and Mech. Prop. _________________________________
to Chem. Analysis and Mech. Prop._______________________________
Thickness Range:
Base Metal: Groove ___________
Fillet _______________
Deposited Weld Metal: Groove Fillet______ Fillet__________
Pipe Dia Range: Groove: ____________________ Fillet _______________
Other ______________________________________________________
GAIL (INDIA) LTD

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DOCUMENT NO.
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Page 22 of 32
EXHIBIT-C
SHEET 2 OF 3
FILLER METALS
F. No.____________________________ Other __________________

A. No. ___________________________ Other __________________
Spec. No. (SFA) ___________________________________________
AWS No. (Class) ___________________________________________
Size of filler metals_________________________________________
________________________________________________________
(Electrodes, Cold Wire, Hot Wire etc.)
Electrode-Flux (Class)_______________________________________
Flux Trade Name __________________________________________
Consumable Inset _________________________________________
Each base metal/filler metal combination should be recorded individually.
WPS NO. ______________
Rev. ________________
POSITIONS:
POST WELD HEAT TREATMENT
Position(s) of Groove _________

Welding Progression: Up__ Down __
Position (S) of Fillet_____________
Temperature Range_____________
PREHEAT
GAS
Preheat Temp. Min. ____________

Inter pass Temp. Max. __________
Preheat Maintenance____________
Shielding Gas (es) ______________

Percent Composition (mixtures)____
Flow Rate______________________
Gas Backing____________________
Trailing Shielding Gas Composition__
Time Range ___________________
ELECTRICAL CHARACTERISTICS
Current AC or DC ____________________ Polarity _______________
Amps (Range) _______________ Volts (Range) _________________
(Amps and volts range should be recorded for each electrode size,
Position, and thickness, etc. This information may be listed in a
tabular form similar to that shown below)
Tungsten Electrode Size and Type _____________________________
(Pure Tungsten, 2% Thoriated, etc)
GAIL (INDIA) LTD

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DOCUMENT NO.
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Page 23 of 32
EXHIBIT-C
SHEET 3 OF 3
Mode of Metal Transfer for GMAW _____________________________
(Spray arc, short circuiting arc. etc.)
Electrode Wire feed speed range ______________________________
TECHNIQUE
String or Weave Bead __________________________________
Orifice or Gas Cup Size_________________________________
Initial and Inter pass Cleaning (Brushing, Grinding, etc.)___________
________________________________________________________
Method of Back Gouging ____________________________________
Oscillation _______________________________________________
Contact Tube to Work Distance _______________________________
Multiple or Single Pass (per side) ______________________________
Multiple or Single Electrodes _________________________________
Travel Speed (Range) ______________________________________
Peening _________________________________________________
Other ___________________________________________________
Weld
Process
Layers
Filler
Metal
Current
Class Dia.
Type
Amp.
Polarity Rating
Travel
Volt
Speed
Range
Range
Others
ex.:
Remarks,
Comments,
Hot wire
Addition,
Technique
Torch
Angle, etc.
GAIL (INDIA) LTD

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DOCUMENT NO.
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Page 24 of 32
EXHIBIT D
Sheet 1 of 3
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON
Company Name ______________________________________________

Procedure Qualification record No._______________ Date ___________
WPS No. ___________________________________________________
Welding Process (es)___________________ Type (s) _______________
(Automatic, Manual, Machines or
Semi Auto)
JOINTS
Groove Design of Test Coupons
(For combination qualification, the deposited weld metal thickness shall be
recorded for each Filler Metal or Process weld)
BASE METAL
Material Spec. _______________ Temperature ___________________

Type of Grade _______________
P. No. _________ to P. No. _____ Time __________________________
Thickness of test coupon _______
Diameter of test coupon ________ Other _________________________
Other ______________________
FILLER METALS
GAS
Weld Metal Analysis A No. ______

Size of Filler metal ____________
Filler Metal E No. _____________
SFA Specification _____________
AWS Classification ____________
Other ______________________
Type of Gas or Gases _____________
GAIL (INDIA) LTD

NEW DELHI
Composition of Gas Mixture ________

Other _________________________

DOCUMENT NO.
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Page 25 of 32
EXHIBIT D
Sheet 2 of 3
POSITION
ELECTRICAL CHARACTERSTICS
Position of Groove ____________

Weld Progression (Uphill, Downhill)
____________________________
Other _______________________
Current _______________________
Polarity _______________________
Amps. ________________________
Tungsten Electrode Size __________
Other _________________________
PREHEAT
TECHNIQUE
Preheat Temp. ________________

Inter pass Temp. ______________
Travel Speed ___________________

String or weave bead _____________
Oscillation _____________________
Multi pass or single pass __________
Single or Multiple electrodes _______
Other _________________________
GUIDED BEND TEST

Type of Figure No.
Result
TOUGHNESS TESTS
Specimen
Notch
Notch Test Impact
No.
Location Type Temp. Value
Lateral
Expansion
%
Mils
Shear
Drop weight
Break
No
Break
FILLET WELD TEST

Result Satisfactory: Yes ____ No ____
Penetration into Parent Metal: Yes ____ No ____
Macro Results ____________________________________________
GAIL (INDIA) LTD

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DOCUMENT NO.
S-04-02-034
REV-0
Page 26 of 32
EXHIBIT D
Sheet 3 of 3
OTHER TESTS
Type of Test ______________________________________________
Deposit Analysis ___________________________________________
Other ___________________________________________________
Welder's Name _________ Check No. _________ Stamp No. _______
Test Conducted by _____________ Laboratory Test No. ___________
We certify that the statements in this record are correct and test welds were
prepared, welded and tested in accordance with the requirements of Section
IX of the ASME Code.
Date ________
Manufacturer ____________
BY _____________________
(Details of record of tests are illustrative only and may be moulded to conform
to the type and number of tests required by codes and specifications)
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-04-02-034
REV-0
Page 27 of 32
EXHIBIT E
Sheet 1 of 2
FOMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING
OPERATOR QUALIFICATION TESTS
Welder Name ____________ Cheek No. ________ Stamp. No. _____
Using WPS No. _____________ Rev. _____________
The above welder is qualified for the following ranges
Variable Record
Actual Values
Process
Process Type
Backing (metal,
Weld metal, flux, etc)
Material Spec.
Qualification Range
Used in Qualification
_________________
_________________
________________
________________
_________________
_______ to ________
________________
________ to ______
Thickness
Groove
Filler
__________________
__________________
_________________
_________________
Diameter
Groove
Filler
__________________
__________________
_________________
_________________
Filler Metal
Spec. No.
Class
F. No.
__________________
__________________
__________________
_________________
_________________
_________________
Position
__________________
_________________
Weld Progression
__________________
_________________
Gas Type
__________________
_________________
Electrical Characteristics
Current
__________________
Polarity
__________________
_________________
_________________
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-04-02-034
REV-0
Page 28 of 32
EXHIBIT E
Sheet 2 of 2
Guided Bend Test Results
Type of Figure No.
Result
Radiographic Test Results (for alternative qualification of groove

welds by radiography)
Radiographic test results ____________________________________
Fillet Weld Test Results

Fracture Test (Describe the location, nature and size of any crack of tearing of
the specimen _____________________________________
Length and Per Cent of Defects ________________ inches _______%
Macro Test - Fusion ________________________________________
Appearance - Fillet Size(ing) _____ x _____ Convexity or Concavity __
Test Conducted by ______________ Laboratory - Test No. _________
We certify that the statements in this record are correct and that the test
welds were prepared, Welded and tested in accordance with the requirements
of Section IX of the ASME Code.
Date ________
Organization_____________
BY _____________________
(Details of record tests are illustrative only and may be modified to

conformation to the type & number of tests required by the Code)
Note:
Any essential variables in addition to those above shall be

recorded
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-04-02-034
REV-0
Page 29 of 32
EXHIBIT - F
RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE
WLDING
1.
Location
2.
Date of Testing
3.
Name of the Contractor/Agency
4.
Material: Carbon steel/Alloy Steel / Stainless Steel

4 A.
Technique: DWSI/SWSI/DWDI
5.
Diameter & Thickness:
6.
Type of Weld Joint:
7.
Radiation Source:
8.
Intensifying Screens/Lead Screens:
9.
Geometric Relationship:
10.
Limit of Film Coverage:
11.
Film Type and Make:
12.
Exposure Time:
13.
Processing:
14.
Density:
15.
Sensitivity:
16.* Type of penatrameter (source side):

17.* Type of penatrameter (Film side):
Signature of Contractor/Agency with Seal
Approval of GAILs Inspector
* Refer Para regarding recommended practice
Penetrameters, Article 22, SE 142, ASME Sec. V
on
placement
of
* For Random radiography lines placement of Penetrameters as per

Article 2, ASME Sec. V is permitted.
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-04-02-034
REV-0
Page 30 of 32
EXHIBIT G
WELDERS IDENTITY CARD
1.
Name:
2.
Identification:
3.
Date of Testing:
4.
Process
5.
Thickness range
6.
Diameter range
7.
F. No.
8.
Date of approval of welding
9.
Position
Approved by:
GAIL (INDIA) LTD

NEW DELHI
PHOTOGRAPH
Employers Signature with seal

DOCUMENT NO.
S-04-02-034
REV-0
Page 31 of 32
EXHIBIT H
TYPE OF SOURCE AND FILMS TO BE USED FOR RADIOGRAPHY
NOMINAL WALL
THICKNESS (T) IN mm
19 T
8 T <19
T<8
Notes:
SHOP WELDED JOINTS
All Materials
Gamma
Ray
Carbon steel Gamma
Ray
All other
Gamma
materials
Ray
Carbon steel Gamma
other
than Ray
Inspection
Class IV *
All
other X Ray
material and
Carbon Steel
of Inspection
Class IV *
AGFA D7 or
equivalent
AGFA D5 or
equivalent
AGFA D4 or
equivalent
AGFA D4 or
equivalent
FIELD WELDS
Gamma
Ray
Gamma
Ray
Gamma
Ray
Gamma
Ray
AGFA D7 or
equivalent
AGFA D5 or
equivalent
AGFA D4 or
equivalent
AGFA D4 /
D2 or
equivalent
AGFA D5 or X-ray with "AGFA D5"

or Equivalent to be used.
equivalent
Gamma Ray with "AGFA

D4/D2" or Equivalent may
be allowed only if in the
opinion of the owner's
inspector Joints are
inaccessible for
X-ray equipment and
radiographic sensitivity is
achieved
Integral to above table
1.
Joints welded in field on Ground Level shall be considered as shop

welded joints.
2.
Very fine grain (High contrast) films slower than the above may have to
be used, if required radiographic sensitivity is not achieved consistently.
3.
AGFA means AGFA GAEVERTS.
Refer Std. Spec. No. S-05-02-012
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-04-02-034
REV-0
Page 32 of 32
INSTRUCTIONS TO VENDOR
FOR
QUALITY DATA REQUIREMENTS
GAIL (INDIA) LTD

NEW DELHI
INSTRUCTIONS TO VENDOR FOR

SPECIFICATION
S-04-02-035
REV-0
Page 1 of 10
CONTENTS
1.0
INTRODUCTION
2.0
PURPOSE
3.0
SCOPE
4.0
DEFINITIONS
5.0
INSTRUCTIONS
6.0
ATTACHMENT
GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION
S-04-02-035
REV-0
Page 2 of 10
1.0
INTRODUCTION
1.1
As a part of services rendered to the Client, GAIL purchases Products/ Services for
Projects on behalf of client (including in house projects) from various vendors.
2.0
PURPOSE
2.1
The purpose of this standard is to describe the vendor Quality Data Requirements
which shall form a part of every Material Requisition (MR)/ Purchase Requisition (PR)
released by GAIL, so as to ensure that all purchased products/ services consistently
conform to planned Quality and projects stated and implied needs are met to Clients
total satisfaction.
3.0
SCOPE
The requirements of this standard are applicable to all Vendors for supply of Packages,
Equipments and Materials which are:
a)
Purchased on behalf of Clients for Projects handled by GAIL.
b)
Purchased for GAILs in house projects.
4.0
DEFINITIONS
4.1
Vendor means the person(s), firm, company, organization from whom GAIL procures
products/ services on behalf of Client, as a part of services to the Client for Projects
handled by GAIL, or for its in house projects rendered.
4.2
Contractor, Sub-Contractor, Sub-vendor, Supplier, Seller, Agents are

considered synonymous to Vendor.
4.3
MR means Material Requisition and PR means Purchase Requisition.
5.0
INSTRUCTIONS
5.1
Quality Assurance Plan (QAP)

Vendor during bidding stage, shall confirm compliance to his QUALITY ASSURANCE
(QA) Plans (consisting of relevant Procedures covering various activities like design and
engineering, material procurement, manufacture, inspection and testing,
documentation, dispatch to site, erection and commissioning where applicable and
maintenance of Quality records) which have already been approved at the time of
vendor enlistment. In the post order stage, the vendor shall confirm the validity of their
QA Plans and submit only revisions/ deviations if any to these plans, to the concerned
GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION
S-04-02-035
REV-0
Page 3 of 10
GAIL Inspection office/ Third Party Inspection Agency for approval within 2 weeks from
the date of receipt of PR.
5.2
Inspection & Test Plan

Vendor shall submit Inspection and Test plan for approval within 2 weeks of PR and
before commencement of manufacture to concerned GAIL Inspection Office/ Third
Party Inspection Agency (TPIA). The Inspection and Test Plan shall also cover bought
out items from sub-vendors.
5.3
Drawing Schedule
Vendor shall submit a total index of drawings and documents required for review/
records based on the Vendor Data Requirement given in the PR along with the
scheduled date of submission of each drawing/ document within 2 weeks from Tele-fax
Letter of Intent. The Drawing schedule shall be specific with regard to drawing/
document No., the exact title and the size of the drawings/documents.
5.4
Progress Report and Schedule

Vendor shall submit Monthly Progress Report and updated procurement, engineering
and Manufacturing Schedule every month, beginning within 2 weeks from Tele-fax/
Letter of Intent.
5.5
Waiver & Deviation

Vendor shall strictly comply with PR stipulations and no deviations shall be permitted.
However, if the need for deviation arises under exceptional circumstances, on the postorder stage, such deviation shall be subject to the approval of GAIL/ OWNER and shall
be submitted through GAIL Regional - Inspection Office in the prescribed WAIVER/
DEVIATION REQUEST format.
5.6
Procurement of Bought out Materials

All critical materials such as casting, forging, fittings, pressure holding parts, electrical
and instrument accessories, etc. shall be purchased by the Vendor from GAIL approved
suppliers meeting Qualification Criteria stipulated if any. Vendor shall submit a list of
bought out materials and sub-vendors for these bought out materials for GAIL approval
within 2 weeks from Tele-fax Letter of Intent.
5.7
Calibration Records
Vendor shall use only calibrated measuring and test instruments and maintain
calibration records. Vendor shall furnish records of calibration of measuring and test
GAIL (INDIA) LTD
NEW DELHI

SPECIFICATION
S-04-02-035
REV-0
Page 4 of 10
instruments including recalibration records to concerned GAIL Inspection Office/ Third

Party Inspection Agency.
5.8
Inspection Test Status

Inspection and Test status of products shall be identified by using markings, authorised
stamps, tags, route cards, inspection records etc. during the course of manufacture to
clearly indicate acceptance/ rejection of tests/stages of inspection performed during its
manufacturing cycle. The identification of inspection and test status shall be
maintained and records thereof shall be submitted as and when demanded by GAIL
Inspection Engineer or Third Party Inspection Agency.
5.9
Quality Records
Vendor shall maintain quality records as per his procedures. Inspection Reports & Test
Record copies- shall be furnished to GAIL Inspection Engineer or Third Party Inspection
Agency.
5.10 Identification and Traceability

Vendor shall establish and maintain a standard written procedure for identifying the
products from applicable drawings, specification or other documents during all stages
of production, delivery and installation, A copy of this Standard procedure shall be
made available at concerned GAIL Inspection office. On job to job basis, vendor shall
confirm its validity and only revisions/ deviations if any, shall be submitted for
approval. The vendor shall ensure that each product which is going in the process of
fabrication / manufacture/ construction/ erection has proper identification throughout
the process including the final output.
5.11 Vendor Documents for GAIL Review/ Records General
i) All Documents shall be in ENGLISH language and in M.K.S. system of units.
ii) Review of the vendor Drawings by GAIL would be only to review the compatibility
with basic designs and concepts and in no way absolve the vendor of his
responsibility to comply with PR requirements, applicable codes, specifications and
statutory rules/ regulations.
iii) Unless otherwise agreed, submission of Documents for Review/ Records shall
commence within 04 weeks from the date of Telefax/ Letter of Intent.
iv) Unless otherwise agreed, vendor shall submit all Drawings and Documents in
number of copies, as stipulated in the Vendor Data Requirement Form, along with
Document Index. The Documents shall be supplied in soft copies where specified.
GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION
S-04-02-035
REV-0
Page 5 of 10
5.11.1 A blank space duly marked measuring 75 mm (W) x 38 mm (H) shall be provided
on the body of all Vendor Drawings for marking of Review Codes by GAIL.
5.11.2 Documents for Review and Documents for Records shall be submitted in separate
folders with separate - covering letter to facilitate expeditious processing at GAIL.
5.11.3 Before forwarding the drawings and documents, vendor shall ensure that the
following information is properly entered in each drawing:
PURCHASE REQUISITION
NAME OF EQUIPMENT
EQUIPMENT TAG NO.
NAME OF PROJECT
CLIENT
DRAWING/ DOCUMENT TITLE
DRAWING/ DOCUMENT NO.
REVISION AND DATE
5.11.4 The Drawing/ Documents shall be checked, approved and duly signed/ stamped by
vendor before -submission. Revision Number shall be changed during submission of
the revised Vendor Documents and all revisions shall be highlighted by clouds.
Before submitting any sub-vendor drawings for review by GAIL, the vendor shall
ensure that these sub-vendor drawings have been reviewed, commented and
stamped by the vendor. Direct submission of sub-vendors drawings without
vendors review shall not be entertained.
5.11.5 While resubmitting the Drawings/ Documents, the vendor shall, in a covering
letter, specifically confirm whether all the comments have been incorporated, if not,
shall furnish reasons with justification.
5.11.6 Multi-sheet Documents other than Drawings shall be submitted in their entirety in
the event of a resubmission even if only few sheets are revised.
5.11.7 Vendor shall forward all Drawings/ Documents (transparencies and printed
matter), to GAIL (India) Limited, Attention: Vendor Print Control, and the copy of
forwarding letter/ transmittal to GAIL Inspection Department as well as to the
Client.
5.11.8 Documents under Review Category
GAIL (INDIA) LTD
NEW DELHI

SPECIFICATION
S-04-02-035
REV-0
Page 6 of 10
Following review codes shall be used for review of Vendor Drawings/ Documents:
Review Code 1 No comments.
Review Code 2
Proceed with manufacture/ fabrication as per commented

document. Revised document required.
Review Code 3
Document does not conform to basic requirements as

marked. Resubmit for review.
Retained for Records
Void
5.11.9 Documents under Records Category

Documents under this category are meant for GAIL Records. These documents
would not be returned to vendor. However, comments, if any, will be
communicated to vendor.
5.12
Final Documentation
5.12.1 Final Drawings/ documents consisting of Technical Data Manual/ Mechanical

Catalogue is a compilation of as built certified, drawings and data, manufacturing
and test records, installation, operating and maintenance instructions. For drawings
where Purchases approval was required, the final certified drawings shall be
included. Final Documents shall be legible photocopies in A4, A3 or A2 size only.
The Purchase Requisition shall also form a part of the final documentation,
5.12.2 Final Documentation shall be bound in Hard board folder(s) of size 265 mm x 315
mm (10 and a half inch x 12 and a half inch) and shall not be more than 90 mm
thickness, it may be of several volumes and each volume shall have a volume
number, index of volumes and index of contents of that particular volume.
5.12.3 Each volume shall contain a Title Block indicating Equipment Tag No., Equipment
Name, P.O./ Purchase Requisition No., Name of Project and Name of Client.
6.0
ATTACHMENT
FORMAT NO. F1 Rev-0:
GAIL (INDIA) LTD

NEW DELHI
WAIVER & DEVIATION REQUEST

SPECIFICATION
S-04-02-035
REV-0
Page 7 of 10
WAIVER/ DEVIATION REQUEST

Format No-F1 Rev-0
WAIVER/ DEVIATION PERMIT
Project___________________________
Originator Ref. No.______________________
Job No.___________________________
Order/ Contract No._____________________
Equipment Title___________________
Item No._______________________________
Vendor/ Contractor Department_________________________

Note: Vendor/ Contractor to note that any delay in processing of concession/ deviation permit
shall be to Vendor/ Contractor account and shall not be used as a reason for extension in
delivery.
Requirement as per specification
Description of Waiver/ Deviation sought
Why the Waiver/ Deviation is required?

Supporting evidence/ calculations enclosed/ not enclosed
Contractual implications if Concession/Deviation is granted
Time Impact
More/Less/No change
Cost Impact
More/Less/No change
Under Present constraints requested Waiver/ Deviation is not optimum for the project and
does not involve any security and safety hazard, and shall meet the stipulated performance
requirements.
Date:
GAIL (INDIA) LTD

NEW DELHI
Signature
Contractor/ Vendor (with seal)

SPECIFICATION
S-04-02-035
REV-0
Page 8 of 10
Decision on Waiver/ Deviation including decision, on time and cost implications

(To be filled by the Inspection engineer at [PROJ/ HO] or Project Manager responsible for
conveying the decision to the Vendor/ Contractor, after resolution)
Date:___________
Signature:_____________
Location:_____________
GAIL (INDIA) LTD

NEW DELHI
Name: ______________

SPECIFICATION
S-04-02-035
REV-0
Page 9 of 10
WAIVER/ DEVIATION REQUEST

Opinion from GAIL Site Supervisor/ inspection engineer.
(Specify whether post-facto approval required for regularization)
Date:__________
Signature:______________
Name: ______________
PROJ/ Site Name:______________
Original forward to: ____________________________________________

(Department/ Group)
Copy to:_____________________________________________________
(Project Manager)
Date:___________
Signature:_____________
Name:______________
Disposal by Department/ Group
Date:___________
Signature:_______________
Name:_______________
Final decision of Project manager alongwith overall review
(Clients decision required/ not required)
Date:___________
Signature:_______________
Name:_______________
Clients decision, if required
Date:___________
Signature:_______________
Name:_______________
Format No-F1 Rev-0

GAIL (INDIA) LTD
NEW DELHI

SPECIFICATION
S-04-02-035
REV-0
Page 10 of 10
STANDARD CONDITIONS FOR ISSUE AND

RECONCILLIATION OF MATRIALS
GAIL (INDIA) LTD

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RECONCILLIATION OF MATERIALS
SPECIFICATION
S 04 02 036
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Page 1 of 9
INDEX
1. CONDITIONS FOR ISSUE OF MATERIALS
2. CEMENT
3. REINFORCEMENT BARS/STRUCTURAL STEEL/PLATES
4. PIPING MATERIAL
5. EQUIPMENTS
6. CABLES
7. LINE PIPES
8. OPTICAL FIBRE CABLE
9. OFC JOINTING KITS
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SPECIFICATION
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Page 2 of 9
1.0
CONDITIONS FOR ISSUE OF MATERIALS

Whenever any material is issued by Owner, following conditions for issue of material in
addition to other conditions specified in the contract shall be applicable:
1.6
1.1
Necessary indents will have to be raised by the Contractor as per procedure laid
down by the GAIL from time to time, when he requires the above material for
incorporation in permanent works.
1.2
Materials will be issued only for permanent works and not for temporary works,
enabling works etc. unless specifically approved by the Engineer-in-Charge and
the same shall not be taken into account for the purpose of materials
reconciliation.
1.3
The Contractor shall bear all other cost including lifting, carting from issue points
to work site/Contractor's store, custody and handling etc. and return of
Surplus/serviceable scrap materials to Owner's storage points to be designated
by the Engineer-in-Charge etc. No separate payment for such expenditure will be
made.
1.4
No material shall be allowed to be taken outside the plant without a gate pass.
1.5
The Contractor shall be responsible for proper storage, preservation and watch &
ward of the materials.
RETURN OF UNUSED MATERIAL

1.6.1 All unused/scrap materials shall be the property of the Owner and shall be
returned in good and acceptable condition size wise, category wise by the
Contractor at his own cost to Owner's Store(s).
1.6.2 No credit will be given to the Contractor for return of scrap. The Contractor
should quote the rates accordingly.
1.6.3 In case the Contractor fails to return unused/scrap materials, then recovery for
such quantity of materials, not returned by the Contractor shall be affected at
following penal rates from the Contractor's bills or from any other dues of the
Contractor to the Owner. Contractor shall make his own arrangements for
weighing the off cuts to be returned to Owner's stores.
1.6.4 Penal Rates for non return of materials :
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Page 3 of 9
Sl.No.
NOTE :
Material
Penal Rates
(a)
Penal rate for non return of

accountable scrap
Issue Rate + 25%

or
Landed Rate + 25% (in
case issue rate are not
indicated in the contract)
(b)
Penal rates for non return of

Unused material/excess scrap
Twice the Issue Rates

or
Twice the Landed Rates
(in case Issue Rates are
not indicated in the
Contract)
1)
Landed Rate shall be arrived from the latest Purchase Order of

respective material received at site by Owner.
2)
In case different penal rates have been indicated in the Contract

(based on Project requirement), the same will supersede the above
rates.
2.0
CEMENT
2.1
Cement as received from cement Manufacturer/ Stockists will be issued to the

contractor. The theoretical weight of cement in each bag for issue purpose will be
considered as 50 Kgs. or 20 bags per MT. However, cement bags weighing upto 4%
less shall be accepted by the Contractors and charged for as full bag. Any type of
cement and in any package as received from Manufacturer/Stockists shall be issued to
the Contractor. No claim whatsoever shall be entertained on this account.
2.2
The Contractor will have to submit their design mix for different grades of concrete,
keeping in view the requirements stipulated in IS:456 and IS 10262, specifically
regarding durability, slump and water cement ratio, and specific gravity of materials
brought to site as analysed in the laboratories. The design shall be based upon absolute
volume method and theoretical consumption of cement shall be worked out on this
basis. For other than concrete items, the coefficients for consumption of cement shall
be adopted as per CPWD practice.
2.3
The permissible variation between Cement actually used on the job and theoretical
consumption worked out on the basis stipulated in above para 2.2 and as determined
by Engineer-in-Charge shall be 3% (Three percent only).
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2.3.1 If the actual consumption is more than 103% of the theoretical consumption,
then recovery at the penal rates for the quantity of cement beyond the limit of
103% of theoretical consumption shall be affected from the Contractor's bill(s) or
any other dues of the Contractor to the Owner.
2.3.2 If the actual consumption is less than 97% of the theoretical consumption then
recovery at the penal rates for the quantity of cement used less than the limit of
97% of the theoretical consumption shall be affected from the Contractor's bill(s)
or any other dues of the Contractor to the Owner, provided that the quality of
the work has been found acceptable by the Owner.
2.4
Unused quantity of cement shall be returned by the Contractor to the Owner's stores in
good condition. In case the Contractor fails to do so, then recovery at penal rates shall
be affected from the Contractor's bill(s) or any other dues of the Contractor to the
Owner.
2.5
The Contractor shall maintain a good store for storing cement issued to him. The
flooring of the storage house, the clearances of cement bags from the side walls/ floor
& stack height etc. shall be as instructed by the Engineer-in-Charge.
2.6
The cement store shall be open for inspection and verification by the Engineer-inCharge or his authorised representative at any time when the Engineer-in-Charge feels
the need to do so.
2.7
Periodical stock taking as decided by the Engineer-in-Charge shall be done by the

Contractor in the presence of Engineer-in-Charge or his authorised representative and a
statement of stocks duly verified shall be submitted to Engineer-in-Charge.
2.8
Empty cement bags shall be the property of the Contractor and shall have to be
disposed off by him.
2.9
Penal rates for excess/less consumption and/or non return of unused quantity w.r.t.
theoretical consumption " allowance as explained in each type of material shall be
charged as given in the Contract.
3.0
REINFORCEMENT BARS /STRUCTRUL STEEL/PLATES
3.1
The scrap allowance for the reinforcement bars/structural steel including steel plate
issued by the Owner, shall be total 3% (2.5% accountable and 0.5% non-accountable)
of the actual consumption as incorporated in the works.
3.2
All reinforcement bars/structural steel/steel plates shall be issued in available

length/shapes/sizes and no claims for extra payment on account of issue of nonstandard lengths/shapes/sizes bending etc. shall be entertained. Reinforcement bars
and structural steel shall be issued on weighment basis as per normal warehousing
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SPECIFICATION
S 04 02 036
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practice. In exceptional circumstances, the reinforcement bars/structural steel, if issued

on linear measurement, the IS coefficients for unit weight shall be considered. For the
purpose of billing and accounting, only linear measurements will be taken and weight
will be calculated as per IS co-efficients in three decimals. The difference in unit weight
as per IS and actual as issued, if any, shall be to Contractor's account and Contractor is
deemed to have considered the same at the time of bidding.
3.3
Reinforcement bars/structural steel/steel plates shall be issued only for those items
where Owner's supply has been specifically mentioned in Schedule of Rates/ Scope of
Supply.
3.4
All reinforcement bars/structural steel except M.S. Plates in length of 2 meters and
above shall be considered as serviceable materials provided the material is in good and
acceptable condition. Reinforcement bars/structural steel section except M.S. Plates in
lengths less than 2M shall be treated as scrap.
3.5
For the purpose of accounting of the plates, all plates measuring not less than 1 Sq.m
in area and having any dimensions not less than 200mm when returned to Owner's
store, will be considered as serviceable material. All other pieces will be treated as
wastage/ scrap. The Contractor will prepare a plate cutting diagram in such a way that
the minimum scrap is generated. Also the cut plates should be used at a proper place to
reduce scrap.
3.6
Above serviceable cut pieces as mentioned in 3.4 & 3.5 above shall be considered as
unused material.
3.7
For non return of unused quantity of material shall be charged at penal rates.
3.8
The wastage generated by the Contractor in excess of the allowable percentage shall
also be charged at the penal rates.
4.0
PIPING MATERIALS
4.1
All pipes shall be issued in available lengths/shapes and no claims for extra payments
on account of issue of non-standard length & shape will be entertained. Pipes shall be
issued on linear measurement basis. All valves, flanges, fittings etc. shall be issued on
number(s) basis. Contractor shall store the materials in such a way so as to avoid
mixing of different types of material and shall maintain complete identification and
traceability at all times.
4.2
The scrap allowance for pipes issued by the Owner shall be 3% (2% accountable +
% non accountable) of the actual consumption as incorporated in the works.
4.3
All pipes in length of 2 meters and above shall be considered as serviceable material
provided the material is in good and acceptable condition and has clear identification
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4.4
and traceability (Manufacturers name, heat number/batch number and test

certificates). Pipes in lengths less than 2 M shall be treated as scrap.
For the non account of pipes drawn by the Contractor over and above the actual
consumption as determined by the Engineer-in-Charge, plus 3% (2% accountable +
% non accountable) thereof to cover the scrap allowance, recovery at penal rate shall
be effected from the Contractor's bill(s) or from any other dues of the Contractor to the
Owner.
4.5
All unused/scrap pipes, valves, flanges, forged fitting like elbows, reducers tees shall be
returned by the Contractor category wise duly cleaned, greased and spec. marked at his
own cost to Owner's stores. In case the Contractor fails to do so then recovery for such
quantity of pipes not returned by the Contractor at the penal rates shall be effected
from the Contractor's bill(s) or from any other dues of the Contractor to the Owner.
5.0
EQUIPMENTS
Various equipment/materials intended for the installation will be received by Owner in
unpacked, skid mounted, crated, packed or loose condition and will be stored in the
warehouses and open yards. In general, materials will be issued to the Contractor in as
received condition. It will be the Contractors responsibility to draw, load and transport
all materials from Owners designated places of issue to the point of installation and
return all packing materials like steel frames, wooden boxes/scrap etc. to Owners
stores.
All materials supplied by the Owner shall be duly protected by the Contractor at his own
cost with appropriate preservative like primer, lacquer coating, grease etc. as required.
6.0
CABLES
6.1
Appropriation of cables shall be done as follows:
6.1.1 All the surplus and serviceable cables out of the cables quantity(ies) issued by the
Owner to the Contractor shall be returned by the Contractor to the Owner's store in
good condition and as directed by the Engineer-in-Charge.
6.1.2 The Contractor shall be allowed a cutting/wastage allowance of 1.5% for power cables
and 3% for the control cables. This cutting/wastage allowance shall be computed on
the length of cables actually laid, measured and accepted.
6.1.3 All cables being returned to store should carry Aluminium sheet tags indicating the size
& type of cable. Cables of less than 15 meters length will be termed as scrap. Cables of
lengths 15 M and above shall be termed as serviceable material & shall be returned size
wise and category wise to the Owner's store in wooden drums. Cables of serviceable
length being returned to stores in drum(s) shall be accepted only after Megger value
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SPECIFICATION
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continuity test and physical measurement is carried out by the Contractor to the
satisfaction of Engineer-in- Charge. Empty cable drums and major packing material (as
decided by Engineer-in-charge) shall be Owners property and shall be returned to
Owners Store/designated place without any additional cost.
6.1.4 While carrying out material appropriation with the Contractor, the above points will be
taken into account. All serviceable materials returned by the Contractor (size wise &
category wise) shall be deducted from the quantity(ies) issued to the Contractor for the
respective sizes. Scrap generated for power cable and control cable shall also be
returned to Owners store on Lot basis.
6.1.5 Material appropriation shall be done & allowable scrap quantity calculated. The wastage
generated by the Contractor in excess of the allowable percentage shall be charged at
the penal rates.
7.0
LINE PIPES
7.1
All coated line pipes as per Line Pipe specifications shall be issued on linear
measurement basis. The line pipes shall be issued in available lengths and shapes and
no claim for extra payment on account of issue of non-standard length and shape will
be entertained. Contractor shall store and maintain the line pipes in proper manner to
avoid mixing of different classes of pipes. Contractor shall maintain complete
identification and traceability at all times. All cut pieces when returned to Owner's
storage points after bevelling, shall be considered as serviceable material provided:
7.1.1 Corrosion Protection Coating is intact.
7.1.2 Pipe pieces have pipe specifications, manufacturers logo/name and heat number
duly authenticated with hard stamp of the authorised inspector as per approved
procedure.
All cut pieces of pipes measuring less than 2 M will be treated as wastage/scrap.
7.2
For the purpose of accounting of coated line pipes, following allowances shall be
permitted:
a)
Unaccountable wastage
0.1%
b)
Scrap (All cut pieces of pipes measuring less than 2 Meter)
0.25%
c)
Serviceable materials (All cut pieces of pipe measuring

2 Meter and above)
0.5%
Scrap shall be accounted at actuals as per site assessment subject to maximum limits
as stated above.
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SPECIFICATION
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The percentage allowance shall be accounted on the basis of pipe book chainage for
main pipeline
7.2.1 Material appropriation shall be done & allowable scrap quantity calculated. The
wastage generated by the Contractor in excess of the allowable percentage shall
be charged at the penal rates as given in the contract.
8.0
OPTICAL FIBRE CABLE

For the purpose of accounting of optical fibre cable, all cut pieces measuring in length
of 40 m and above when returned to Owner's storage points shall be treated as
serviceable materials. All cut pieces of cable measuring less than 40 M will be treated as
scrap.
For the purpose of accounting of OFC (Optical Fibre Cable) following allowances shall be
permitted:
(i) Unaccountable wastage
0.1%
(ii) Scrap (All cut pieces of cables measuring less than 40 M)
0.25%
(iii) Serviceable material (measuring 40M and above)
0.25%
Material appropriation shall be done & allowable scrap quantity calculated. The wastage
generated by the Contractor in excess of the allowable percentage shall be charged at
the penal rates as given the contract.
9.0
OFC JOINTING KITS

The Contractor shall make a schedule for use of Cable jointing kits and get the same
approved from Engineer-in-charge. The quantity mentioned in this schedule will be
termed as planned usage quantity which shall be issued to the Contractor. However,
any jointing based on site requirements as decided by Engineer-in-charge shall be
included in planned quantity.
Any unplanned jointing required to be carried out by Contractor due to reasons not
attributable to GAIL shall be issued from spare quantity, if available with Owner. Such
unplanned OFC Jointing Kits shall be charged from the Contract at penal rates.
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SPECIFICATION
FOR
PIPELINE INFORMATION MANAGEMENT SYSTEM
GAIL (INDIA) LTD

NEW DELHI

PIPELINE INFORMATION MANAGEMENT
SYSTEM
SPECIFICATION
S-04-02-037
REV-0
Page 1 of 6
CONTENTS
SI.No.
Description
1.0
INTRODUCTION
2.0
DETAILED SCOPE OF PIPELINE INFORMATION

MANAGEMENT SYSTEM
3.0
SCOPE OF CONTRACTORS RESPONSIBILITY
4.0
EXPERIENCE CRITERIA
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SPECIFICATION
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1.0
INTRODUCTION
1.1
The Pipeline Information Management System (PIMS) shall be used for the construction
progress on a real time basis and shall be updated daily. The progress needs to be
displayed electronically on a web based format s per the scope of work detailed below.
2.0
DETAILED SCOPE OF PIPELINE INFORMATION MANAGEMENT SYSTEM
2.1
Construction management
2.2
The scope of work includes all materials, hardware, software, manpower, services etc.
required for customized pipeline data information management solution for the Pipeline
Project. The work shall include the following as the minimum:
a.
Progress of all construction activities (ROU grading to pre-commissioning)

-Pre construction survey, ROU clearing and grading
-Pipe history
-Trenching
-Stringing
-Bending
-Welding including weld repair details
-NDT
-Joint Coating
-Concrete coating
-Lowering (including OFC laying)
-All crossings and HDD
-TCP/PCP
-Back Filling & Tie-in
-OFC Jointing
-Hydrotest
-Pre-commissioning activities
-Station works
-Restoration
Details of any major repairs on pipe/coating conducted at pipe ware house or at site
shall also be indicated.
b.
Progress of each construction activity to be tracked separately and all procedures
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& reports shall be linked to the data.

c.
2.3
Reporting formats shall be customized for the Pipeline project.
SCANNING, CATALOGUING AND DATA ENTRY

Scanning, cataloguing, indexing and retrieval of all project related documents including
but not limited to the following:
2.3.1 Pipe information

a.
Manufacturing history (including all relevant inspection & test documents) of

pipes & plates.
b.
Pipe reconciliation statement with supporting document
2.3.2 Material Acceptance

a.
Joint coating material Manufacturers Test certificates
b.
Filler Metal/electrode Manufacturers Test Certificates and site qualification tests

reports
2.3.3 Procedure and Reports

Approved procedures, Job Procedures, welding procedures specification &
qualification, QAPs and ITPs for all pipeline activities including Terminals, SV Stations,
IP Stations etc. Scanning and digitisation of Gazette notifications available with the
COMPANY. All construction activity reports including crossings.
2.3.4 Cadastral survey documents
a.
b.
c.
d.
e.
Surveys nos.
Ownership area of affected survey no. in ROU
Permanent feature along centre of pipeline
Village maps, Talukas, Districts etc.
Nearest police station with details, hospital, fire station, village panchayat,
district details
2.3.5 Land acquisitions details

a.
b.
c.
d.
The land owner details including the permanent and alternative address
Mutation details
Land usage details of the property owner including the crop details
The information on the compensation paid to owner.
2.3.6 Clearance and Restoration

Clearance and restoration acceptance from statutory authorities such as Forest
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SPECIFICATION
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Department, Railways, PWD etc.

2.3.7 Hydrotesting and Precommissioning
All relevant hydro-testing and pre -commissioning documents/data including (but not
limited to)
a.
b.
c.
d.
e.
f.
g.
Water filling, Pressurization and Hydrotest reports

Dewatering Inspection reports
Magnetic Cleaning reports
EGP reports
Drying Inspection reports
Swabbing Inspection reports
Inertisation/ Preservation/ Inspection/ commissioning reports
2.4
Management Information System
2.4.1
Pre-construction and post-construction linkage with videography, digital photographs

at terminals/stations, crossings (at least 100m on either side of railway, SH, NH and
river crossings) and SV stations to route map shall be provided. The following shall be
linked to schematic route map to provide information during operation of the pipeline.
a.
b.
c.
d.
e.
f.
g.
h.
2.5
Pipe book with all details

As built Alignment sheets
As built drawings for crossings and their photographs
Station General Arrangement Drawings(IP,SV, terminals),isometrics, layout, P&ID
etc
Data Sheet of Equipment such as filters, metering, scraper traps etc.
Test certificates Pipe, pipe coating, equipment, contractor supplied items, etc.
All SV/ IP Stations/ turning points/ crossing/ km posts/ warning signs/ scraper
stations shall be geo-referenced.
All required scanning, cataloguing and data entry as required for successful
operation of the system.
Other requirement of pipeline information management system
2.5.1 The software system/package of data information management system shall be able to
function on a LAN/ WAN, restricted to 20 users, with adequate provision of security. the
software package should be a web based system providing simultaneous access to the
CONTRACTOR & GAIL.
2.5.2 The system shall enable quick retrieval and printing of relevant pipeline data/ as built
information through a suitable application.
2.5.3 The proposed system shall be equipped with security facilities to prevent
datatampering, data theft, sabotage and virus attack.
2.5.4 The CONTRACTOR shall collect, store, classify, handle and protect all input data and
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SPECIFICATION
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acquired data in good shape till completion and handing over of finished work.
CONTRACTOR shall not make any unauthorised alteration, modification and copies of
any input data unless explicitly authorised by the COMPANY. All input and acquired data
shall be returned to the COMPANY at the completion of work in its original form.
3.0
SCOPE OF CONTRACTORS RESPONSIBILITY
3.1
The CONTRACTOR shall be solely responsible for arranging all resources, facilities and
logistic supports etc. required to complete the work under this contract. In broad, the
CONTRACTOR shall be responsible for providing the following:
a.
Establishment of a suitable onsite office with proper storage and security

arrangement.
b.
Deployment of requisite manpower for project implementation (onsite and

offsite).
c.
Deployment of all requisite hardware (servers, computers, printers, scanners,

UPS, etc.) loaded with requisite software to run applications required for the
project implementation
d.
All consumables for scanning, printing, storing, and creation of backup data
CDs/DVDs.
e.
Establishment of suitable communication network with a provision of Internet

connection for communication, email and uploading and downloading of scanned
documents.
f.
The integrity and confidentiality of the COMPANYs information assets are to be

maintained.
The scope of work shall also include any other item/Work required to complete the
work in all respects as per specifications and instructions of COMPANYs representative
whether specifically mentioned here in or not, but required to fulfill the intended
purpose of this tender document and this specification.
4.0
EXPERIENCE CRITERIA
The bidder shall submit information about the Agencys experience in providing such a
solution. A project specific detailed methodology to carry out all the above activities
shall be submitted for COMPANYs review. The subcontractor and his software shall
be approved by COMPANY.
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SPECIFICATION
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TECHNICAL NOTES FOR PIPES
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TECHNICAL NOTES
S 05 02 001
REV- 0
Page 1 of 9
TECHNICAL NOTES FOR PURCHASE OF PIPES

1.0
GENERAL
1.1
All pipes and their dimensions, tolerances, chemical composition, physical properties, heat
treatment, hydrotest and other testing and marking requirements shall conform to latest
codes and standards specified in the material requisition (MR). Deviation(s), if any, shall be
clearly highlighted in the offer.
1.2
Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material
specifications. Test report shall also be furnished for any supplementary tests as specified in
the
MR and clauses 1.10 & 1.11.
1.2.2 Material test certificates (Physical property, chemical composition & heat treatment report)
shall also be furnished for the pipe supplied.
1.2.3 PMI shall be performed as per the scope and procedures as defined in the GAIL standard
spec. for PMI at vendors work
1.3
Manufacturing Process
1.3.1 Steel made by acid Bessemer process shall not be acceptable.

1.3.2 All longitudinally welded pipes other than IS 3589 should employ only automatic welding.
1.4
Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters

respectively.
1.5
a.
Seamless and ERW pipes shall not have any circumferential seam joint in a
random length. However, in case of E.FS.W. pipe, in one random length one
welded circumferential seam of same quality as longitudinal weld is
permitted. This weld shall be at least 2.5 m from either end. The longitudinal
seams of the two portions shall be staggered by 900. Single random length in
such cases shall be 5 to7 m.
b.
Unless otherwise mentioned in the respective material code, E.FS.W. pipes <
36 shall not have more than one longitudinal seam joint and E.FS.W pipes
36 shall not have more than two longitudinal seam joints.
1.6
Pipe with screwed ends shall have NPT external taper pipe threads
conforming to ASME/ ANSI B1,20.1 up to 1.5 NB & IS 554 for 2 to 6
NB.
1.7
Pipe with beveled end shall be in accordance with ASME B 16.25. Weld
contour shall be as follows:
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TECHNICAL NOTES
S 05 02 001
REV- 0
Page 2 of 9
Material
Wall Thickness
Weld Contour
Carbon steel (except Low Up to 22 mm

Temp. Carbon Steel)
> 22 mm
Figure 2 Type A
Alloy Steel, Stainless Steel Up to 10 mm

& Low Temp. Carbon
> 10 mm & Up to 25 mm
Steel
Figure 4
> 25 mm
Figure 3 Type A
Figure 5 Type A
Figure 6 Type A
1.8
Galvanised pipes shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A 153.
1.9
All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types
of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilized
heat treatment shall be carried out subsequent to the normal solution annealing. Soaking
time & holding temp. for stabilizing heat treatment shall be 9000 C & 4 hrs respectively.
1.10
I.G.C Test for Stainless Steel
1.10.1 For all austenitic stainless steel pipes intergranular corrosion test shall have to be conducted
as per following:
ASTM A 262 Practice B with acceptance criteria of 60 mils/year (max.).
OR
ASTM A 262 Practice E with acceptance criteria of No cracks as observed from 20X
magnification & Microscopic structure to be observed from 250X magnification
1.10.2 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (eg. SS 309, 310, 316, 316 H etc.) ASTM A 262 Practice C with
acceptance criteria of 15 mils/year (max) shall have to conducted.
1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from
each solution annealing lot; one set corresponding to highest carbon content and the other
set corresponding to the highest pipe thickness. When testing is conducted as per Practice
E, photograph of microscopic structure shall be submitted for record.
1.11
All welded pipes indicated as CRYO & LT in MR shall be impact tested per
requirement and acceptance criteria of ASME B 31.3. The impact test temperature shall be
(-)1960 C & (-) 450 C for stainless steel and carbon steel respectively unless specifically
mentioned otherwise in the MR.
1.12
Pipes under NACE category shall meet the requirements given in MR-01-75
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S 05 02 001
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1.13
Specified heat treatment for carbon steel and alloy steel and solution annealing for stainless
steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot
shall be restricted to maximum two by approved repair procedure.
1.14
For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be 20
%.
1.15
All 1 Cr 0.5 Moly & 1.25 Cr 0.5 Moly seamless pipes shall be normalized and tempered.
1.16
For all welded Alloy steel pipes with mandatory requirement of heat treatment and
radiography, radiography shall be performed after heat treatment.
2.0
IBR PIPES
2.1
IBR Documentation :
2.1.1 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 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.
2.1.2 For material 1 Cr Mo (ASTM A335 Gr.P11 / A691 Gr. 1 Cr) & 2 Cr 1 Mo
(ASTM A 335 Gr. P22 / A 691 Gr. 2 Cr), Form III-A approved by IBR shall include the
tabulation of Et, Sc & Sr values for the entire temperature range given below. Et, Sc & Sr
values shall be such that throughout the temperature range
Et / 1.5
Sr / 1.5
Sc
SA
Where,
SA
Allowable stress at the working metal temperature
Et
Yield Point (0.2 % proof stress at the working metal temperature)
Sc
The average stress to produce elongation of 1% (creep) in 100000 hrs at the

working metal temperature.
Sr
The average stress to produce rupture in 100000 hrs at working metal

temperature and in no case more than 1.33 times the lowest stress to produce
rupture at this temperature.
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SA (psi)
Temp
500
(oF)
Material
600
650
700
750
800
850
900
950
1000
1050
1100
A335 Gr.
P 11
17200
16700
16200
15600
15200
15000
14500
12800
9300
6300
4200
2800
A691 Gr.
1 Cr
18900
18300
18000
17600
17300
16800
16300
15000
9900
6300
4200
2800
A 335 Gr.
P22 /
A691 Gr.
2 Cr
17900
17900
17900
17900
17900
17800
14500
12800
10800
7800
5100
3200
Note:
2.2
SA values given above are as per ASME B 31.3 1999. Values shall be as per
the latest edition prevailing.
For carbon steel pipes under IBR the chemical composition shall conform to the following :
Carbon (max)
0.25 %
Others (S, P, Mn)
As prescribed in IBR regulation.
The chemical composition as indicated in this cluse is not applicable for pipes other than
IBR services.
3.0
HYDROSTATIC TEST
Refer Annexure I
4.0
MARKING AND DESPATCH
4.1
All pipes shall be marked in accordance with the applicable codes, standards and
specifications. In addition the purchase order number, the item code & special condition like
IBR, CRYO, NACE etc. shall also be marked.
4.2
Pipes under IBR, CRYO, NACE, H2 (Hydrogen) shall be painted in red stripes,
light purple brown stripes, canary yellow stripes and sea green stripes respectively
longitudinally throughout the length for easy identification. Marking of pipes
circumferentially for sizes 1 and below at one meter interval along the length of pipes is
also acceptable.
4.3
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.
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4.4
Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
4.5
Pipes shall be protected from rust, corrosion and mechanical damage during transportation,
shipment and storage.
4.6
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.
4.7
Both ends of the pipe shall be protected with the following material:
Plain end
Bevel end
Threaded end
:
:
:
Plastic Cap
Wood, Metal or Plastic Cover
Metal or plastic threaded cap
4.8
Pipes may be provided with plastic push fit type end caps/ steel caps without belt wire..
4.9
Plastic caps can also be used as end protector for galvanized pipe ends.
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Page 1 of 3
ANNEXURE I
3.0
HYDROSTATIC TEST
3.1
All pipes shall be hydrostatically tested.
3.2
The mill test pressure shall be as follows :
3.2.1 Seamless, E.R.W. & Spiral welded :

a)
Carbon Steel
Material Std.
ASTM A 106 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
b)
ASTM A 530
API 5L
API 5L
API 5L
ASTM A 530
ASTM A 530
Seamless Alloy Steel

Material Std.
ASTM A335 Gr.. P1, P12, P11, P22,

P5, P9
ASTM A268 TP 405, TP 410
c)
Test Pressure Std.
Test Pressure Std.

ASTM A 530
ASTM A 530
Seamless Stainless Steel

Material Std.
ASTM A312 Gr. TP 304, 304L, 304H,

316, 316L, 316H, 321, 347
d)
Seamless Nickel Alloy
Material Std.
ASTM B161 UNS No. 2200
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
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Test Pressure Std.

ASTM A 530
Test Pressure Std.

ASTM B161
ASTM B165
ASTM B167
ASTM B407
API 5L
API 5L
API 5L
ASTM A 530
ASTM A 530
TECHNICAL NOTES
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Page 2 of 3
e)
Welded Nickel Alloy

Material Std.
Test Pressure Std.
ASTM B725 UNS No. 2200, 4400

ASTM B725
ASTM B517
ASTM B514
3.2.2 Electric Fusion Welded

a)
Carbon Steel & Alloy Steel E.FS.W (16 & above)

Material Std.
Test Pressure Std.
API 5L Gr. B
ASTM A671 Gr.CC65, 70 (Cl.32)
ASTM A672 Gr.C60, 65, 70 (Cl.12, 22)
ASTM A671 Gr.CF60, 65, 66, 70 (Cl.32)
ASTM A691 Gr.1/2 Cr, 1Cr, 1 Cr, 2
Cr, 5Cr, 9Cr (Cl.42)
b)
P = 2ST / D
S = 90% of SMYS
Except for API 5L Gr. B
S = 85% of SMYS
For API 5L Gr. B
T = Nominal Wall Thickness
D = O.D of Pipe
Stainless Steel E.FS.W (2 to 6) :
The hydrostatic test pressure in kg/cm2 for the following materials shall be as given below :
Material Gr. 1 :ASTM A 312 TP 304 / 304 H/ 316 / 316H/ 321/ 347 welded.
Material Gr. 2 :ASTM A 312 TP 304 L/ 316L welded.
Size
2
3
4
6
Pipe Schedule : 10S

Material
Material
Gr.1
Gr.2
100
80
80
60
80
50
65
35
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Pipe Schedule : 40S

Material
Material
Gr.1
Gr.2
155
130
155
130
155
130
90
75
Pipe Schedule : 80S

Material
Material
Gr.1
Gr.2
230
190
230
190
230
190
155
130
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Page 3 of 3
c)
Stainless Steel E.FS.W (8 and above)

Material Std.
Test Pressure Std.
P = 2ST/D
ASTM A358 TP 304L, 304, 304H,
316L, 316, 316H, 321, 347 (Classes 1, 3 S = 85% of SMYS
& 4)
D = O.D. of pipe
P = 2ST/D
ASTM A358 TP 304L, 304, 304H,
316L, 316, 316H, 321, 347 (Classes 2 & S = 72% of SMYS
5)
D = O.D. of pipe
3.2.3 Carbon Steel Pipes to IS Standards:
Material Std.
IS 1239
IS 3589
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IS 1239
IS 3589
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TECHNICAL NOTES
FOR
PIPELINE VALVES
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CONTENTS
S. NO.
TITLE
1.0
GENERAL
2.0
DOCUMENTATION
3.0
4.0
OPERATION
5.0
6.0
RADIOGRAPHY OF CAST VALVES
7.0
IBR CERTIFICATION
8.0
MARKING
9.0
DESPATCH
10.0
ATTACHMENTS
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1.0
GENERAL
1.1
Vendor shall supply valves in accordance with the valve specification sheets along with
auxiliaries, if any, such as gear operator, bypasses, drains etc. wherever specified in the
specification sheets, subject notes and other enclosures to the material requisition (MR).
1.2
Vendor shall quote in strict accordance with the valve data / specification sheets, subject
technical notes and all other enclosures to the MR. Deviations to the specification / data
sheets, subject technical notes and other enclosures of the MR, if any, shall be asked as
explained in clause 2.0.
1.3
All codes and standards for manufacture, testing, inspection etc. shall be of latest editions.
2.0
DOCUMENTATION
2.1
Vendor shall submit the following with the offer:
2.1.1
Manufacturers complete descriptive and illustrative catalogue / literature.
2.1.2
Detailed dimensioned cross section drawing with parts /material lists, weight etc.for the ball
valves, plug valves, butterfly valves, diaphragm valves and valves to manufacturers standard.
2.1.3
Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator,
motor, extension bonnet, extended stems with stands, bypass etc. giving major salient
dimensions.
2.1.4
One copy of the valve specification sheets signed as Accepted by the manufacturer with all
deviations marked clearly.
2.1.5
If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve
specification sheets as Regret or No Deviation.
2.1.6
For subject notes, if there is any deviation, the same shall be listed clause-wise. Even clauses
which are acceptable shall be categorically confirmed as Accepted.
2.1.7
On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely
to be rejected.
2.2
The following documents shall be submitted after placement of the order:
2.2.1
Vendor shall submit for approval drawings mentioned in clauses 2.1.2 & 2.1.3 before start of
manufacture. No other drawing shall be submitted for approval.
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2.2.2
Test report shall be supplied for all mandatory tests as per the applicable code. Test reports
shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.
2.2.3
Material test certificates (physical properties, chemical composition & heat treatment report)
of the pressure containing parts shall be furnished for the valves supplied. Material test
certificates for the other parts shall also be furnished for verification during inspection.
3.0
3.1
Valve shall be designed, manufactured, tested, inspected and marked as per the
manufacturing standards; design codes and standards (latest editions) indicated in the
respective valve specification sheets. Any conflict between the requisition, enclosures,
specification sheets and referred standard codes shall be brought to the notice of the purchaser
for clarifications. But generally, specification sheets and enclosures of the requisition
including subject notes shall govern. After issue of the Purchase Requisition (PR) no
deviation to specification / standards shall be permitted through vendor drawing approval.
Approval of drawings shall be valid only for design / constructional features.
3.2
All flanged valves shall have flanges integral (except forged valves) with the valve body.
Flange face finish shall be normally specified in the valve specification sheet as serrated
finish, 125 AARH etc. The interpretation for range of face finish shall be as follows:
Stock Finish
Serrated Finish / Smooth Finish/ 125 AARH
AARH
Extra Smooth Finish / 63 AARH
3.3.
1000 in AARH max.
Serrations with 125 to 250 in
32 TO 63 in AARH
For all weld end valves with bevel end as per ASME B16.25 the contour of bevel shall be as
follows:
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3.4
For flanged valves with ring joint flanges the hardness shall be as follows
Flange Material
Min. Hardness of Groove (BHN)
Carbon Steel
140
1%Cr to 5%Cr
150
Type 304, 316. 321, 347
160
Type 304L, 316L
140
3.5
Following requirements for check valves shall be met over and above the valve spec sheet
requirements:
3.5.1
Unless specified otherwise in the data sheet all check valves 3 & above (except in 900#,
1500# & 2500# rating) shall have a drain boss at location G (Refer Fig.No.1 of ASME
B16.34). A tapped drain hole with plug shall be provided as per ASME B16.34. Threads shall
be as per ASME B1.20.1 (Taper) NPT.
3.5.2
Wherever check valve disc assembly is supported from the cover of the check valves the
following shall be ascertained.
i)
Positive location /positioning of cover must he provided to ensure correct alignment

of the valve disc.
ii)
Hinge pin design must permit accurate alignment of the disc and valve seat.
3.5.3
For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and
other such standard devices.
3.6
If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion
resistance of the seat ring base material shall be at least equal to the corrosion resistance of
the material of the shell.
3.7
Following valve bypass requirements shall be met:
3.7.1
By-pass requirement for Gate valves is indicated in the respective data sheets. As a rule, the
following shall be followed:
ANSI 150 Class
On sizes 26 and above
ANSI 300 Class
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ANSI 600 Class
ANSI 900 Class
ANSI 1500 Class
ANSI 2500 Class
3.7.2
The by-pass piping arrangement shall be such that clearance between main valve body and
by-pass assembly shall be the minimum possible for layout reasons.
3.7.3
By-pass valve shall be a globe valve. The sizes shall be as under:

On main valve 4
1/2 or more
On main valve > 4 but < 10 :
3/4 or more
On main valve > 10
1 or more
The by-pass arrangement shall be as specified in Specification Sheet No.12 - 13.

3.7.4
Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with
by-pass shall have the direction of flow marked on the main valve. By- pass attachment to the
main valve body shall not be screwed. All fillet welds for bypass installation shall be 100%
examined by DP/ MP test.
3.8
Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of
casting but not vice-versa.
3.9
Material of construction of yoke shall be minimum equivalent to body / bonnet material.
3.10
Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However,
integral stern of cast stainless steel ball valve is acceptable.
3.11
Stelliting / Hardfacing by deposition, shall be minimum 1.6 mm. Renewable seat rings shall
he seal welded.
3.12
For Low Temperature & Cryogenic valve requirements, refer Specification. @ Sheet no-17.
3.13
Valves under NACE category shall meet the requirements specified in MR unless
otherwise specified.
3.14
For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted
as per the following:
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3.15.1 ASTM A262 Practice B with acceptance criteria of 60 mils/year (max.) for all materials forged, rolled, wrought and casting.
Qr
ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20X
magnification for all materials other than castings. Microscopic structure to be observed
from 250X magnification in addition.
3.15.2 When specifically asked for in MR for high temperature application of some grades- of
austenitic stainless steel (e.g. SS 309, 310, 316, 316H etc) ASTM A262 Practice C with
acceptance criteria of 15 mils/year (max.) shall be conducted.
3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn
from each solution annealing lot. One set shall correspond to the highest Carbon content and
the other to the highest pressure rating. When testing is conducted as per practice E,
photograph of the microscopic structure shall be submitted for record.
3.16
All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition.
Stabilising heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilising heat treatment shall be 900C and 4
hours respectively.
3.17
Spiral wound bonnet gaskets are to be provided with inner/ outer ring except when
encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in
case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of
spiral touches the bolts ascertaining the centering.
3.18
Ball/ Plug/ Butterfly Valves:
3.18.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS 6755 Part II shall be
carried out on soft seated ball, plug & butterfly valves and also on lubricated plug valves. The
test shall be witnessed and certified by a third party inspection agency like Lloyds, B.V.,
DNV etc. The vendor has to submit test certificate for the particular design of the valve
offered.
3.18.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated
valves.
3.18.3 Soft-seated ball, plug & butterfly valves shall he supplied with antistatic devices.
3.18.4 Soft-seated BW / SW end ball valves shall have a 100mm long seamless pipe nipple welded
to each end of the valve. Nipples are to be welded prior to assembling Teflon seats I seals.
Specifications of the nipples shall be as indicated in the MR.
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3.18.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the
corresponding ANSI class (except 10 onwards in Class 150 where the face-to-face
dimensions shall be as per API 6D long pattern).
3.18.6 The ball of ball valve shall not protrude outside the end flanges of valve.
3.18.7 Ball valves shall be of floating ball/ trunnion mounted type as per following:
150#
8 & below
Floating ball
10 & above
Trunnion mounted
4 & below
Floating ball
6 & above
Trunnion mounted
300#
600#
& above
1.5 & below Floating ball

2 & above
Trunnion mounted
3.18.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be
limited to one size lower than the nominal bore.
3.19
The MOVs are to be installed in an open area and the actuators shall be suitable for all
weather conditions. The testing of complete assemblies of MOVs along with the actuators
shall be done by the supplier at his works. Torque details for MOVs shall be furnished by the
bidder / supplier in the format attached with the MR.
4.0
OPERATION
4.1
Generally the valves are hand wheel or lever operated. Gear operation shall be provided as
under:
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For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure
balance plug valves manufacturers recommendation shall be acceptable provided the
requirements specified in clause 4.6 are met.
4.2
Gear operator shall be as under, with position indicators for open / close positions and with
limit stops. (Limit stops are not applicable for gate and globe valves).
For Gate / Globe / Diaphragm
Valves
Totally enclosed bevel gear in grease case with grease

nipples / plugs.
For Ball / Plug / Butterfly

Valves
Totally enclosed helical worm or combination of helical

worm and spur gear in grease case with grease nipples /
plugs.
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4.3
Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear
operator, he shall highlight such case(s).
4.4
Gear operator shall be so designed as to operate effectively with the differential pressure
across the closed valve equal to the cold non-shock pressure rating.
4.5
Ball, plug and butterfly valves, even with wrench or lever operators shall have Open
position indicators with limit stops.
4.6
Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on
either side. Effort to operate shall not exceed 35 Kg at hand-wheel periphery. However,
failing to meet the above requirements, vendor shall offer gear operated valve and quote as
per clause 4. 3.
5.0
5.1
Every valve shall be subjected to all the mandatory tests and checks called in the respective
codes / data sheet by GAIL inspection or any third party as approved by the owner. For IBR
valves refer clause 7.0.
5.2
Every valve, its components and auxiliaries must be subjected to all the mandatory tests and
checks called for in the respective codes, data sheets etc. by the manufacturer.
5.3
Though the extent of inspection shall be as under, exact extent with hold points shall he
decided by GAIL inspection office and recorded in the form of inspection plan. In case of
third party inspection, the inspection plan shall be approved by the purchaser.
Forged Valves:
1.
2.
3.
4.
5.
Visual and dimensional inspection.

Review of material test certificates.
Any mandatory or supplementary test.
Hydrostatic test on 10% valves selected on random basis.
Strip check is required for 1 % of total ordered quantity of valves (min. 1 No.) against
each specification lot.
Cast Steel Valves:

1.
2.
3.
4.
5.
Visual and dimensional inspection.

Review of material test certificates.
Review of radiographic reports or any other NDT tests wherever applicable as per
data sheet.
Any mandatory or supplementary test.
Hydrostatic test 100% for body, 10% other test.
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6,
Strip check is required for 1 % of total ordered quantity of valves (mm. 1 No.) against
each specification lot.
Samples for strip check shall be selected at random and shall generally be in the
size in the lot.
highest
5.4
In case of motor operated or actuator operated valves, functional / operational checks as per
the requirements of the specifications shall be made on each valve.
5.5
Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the Specification for Positive Material Identification (PMI) at Vendors Works
6.0
RADIOGRAPHY OF CAST VALVES
6.1
Valve castings shall undergo radiographic examination as specified below. However, for sizes
24 & below in 150# and 16 & below in 300#, radiography percentage specifically
mentioned in individual valve material spec sheet shall govern.
Material
All
Rating
Size Range
Radiography
150#
24 and below
NIL
26 and above*
100%
16 and above
NIL
18 and above
100%
All Sizes
100%
300#
600# & above
*No radiography is required for valves of size 26 in cooling water service.

Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies
10% or 20% etc. of number of valves ordered against each item number with a minimum of
one valve against each item.
6.2
Radiography procedure, areas of casting to be radiographed shall be as per ASME B16.34

and acceptance criteria shall be as per ASME B16.34 Annexure-B. However for areas of
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casting to be radiographed for types of valves not covered in ASME B16.34, vendor shall
enclose details of areas to be radiographed in line with ASME B16.34.
6.3
For random radiography wherever specified in individual data sheets, the sampling shall be as
per size of the quantity ordered for each foundry.
6.4
Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X- ray
/ -ray to get the required sensitivity.
6.5
Over and above the stipulations laid down in clauses 6.1, 6.2, 6.3 & 6.4, all valve castings
when sourced indigenously shall only be procured from foundries approved by GAIL.
7.0
IBR CERTIFICATION
7.1
For valves described IBR, valves shall be in accordance with the latest IBR (Indian Boiler
Regulation) including the requirements specified in the specification
7.2
For SW/ BW end carbon steel valves under IBR, the chemical composition shall conform to
the following:
Carbon (Max)
0.25%
Others (S, P, Mn)
::
As per IBR regulations
The above composition is not valid for non-IBR valves.

7.3
Valves coming under the purview of IBR (Indian Boiler Regulations) shall each be
individually accompanied by IBR certificate original in Form Ill-C duly approved by IBR
authority / local authority empowered by the Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
7.4
All IBR valves shall be painted red in body-bonnet/ body-cover joint.
8.0
MARKING
8.1
Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the
standard referred in specification sheet as applicable. Vendors name, valve rating, material
designation, nominal size, direction of flow (if any) etc. shall be integral on the body.
8.2
Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely
attached to the valve body.
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8.3
Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
or copper which cause corrosive attack on heating.
8.4
Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).
9.0
DISPATCH
9.1
Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
9.2
Valves shall be protected from rust, corrosion and any mechanical damage during
9.3
Rust preventive on machined surfaces to be welded shall be easily removable with a

petroleum solvent or shall not be harmful to welding.
9.4
Each end of valve shall he protected with the following materials

Flange Face
Bevelled End
SW & SCRD.End
:
:
:
Wood or Plastic Cover

Wood or Plastic Cover
Plastic Cap
9.5
End protectors of wood/ plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than the outside diameter of the flange. However plastic caps
for SW & SCRD end valves shall be press fit type.
9.6
End protectors to be used on bevelled end shall be securely and tightly attached.
9.7
For special service valves additional requirement of dispatch shall be prescribed in data sheet.
10.0
ATTACHMENTS (Cut out the irrelevant attachments)

Bypass Piping Arrangement
Special Requirement for Low temperature and Cryogenic Valves
Data Sheet Format for Torque Values of MOVs
GAIL (INDIA) LTD

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TECHNICAL NOTES
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S 05 02 002
Page - 13 -of 17
BYPASS PIPING ARRANGEMENT
NOTES:
The orientation & location of hand wheel of bevel gear operator & the bypass
arrangement shall be strictly as per this sketch.
2.
The bypass pipe ends shall be socket/butt welded to the body wall of the main valve.
3.
The bypass arrangement shall be properly clamped to & supported by the body of the
main valve.
4.
Basic design of bypass shall be to MSS-SP-45 & ASME B16.34.
5.
Material of bypass pipe & 90 elbows shall be same or equivalent to the body material
of the Valve.
6.
Vendor shall furnish dimensions L1 to L8.
GAIL (INDIA) LTD
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TECHNICAL NOTES
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Page - 14 -of 17
SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES

1.0
Scope
All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS (CRYO)
material are categorized as cryogenic valves. All these valves shall have extended bonnet as
per BS 6364 except check valves. Valves shall be suitable for installation in any position (on
vertical, horizontal or skewed pipe line).
Following qualification criteria shall be met by the valve vendors to quote valves for
cryogenic services.
2.0
Qualification Criteria
Both cryogenic test (clause 2.1) and reference list (clause 2.2) together, as indicated herein
shall be considered for vendor qualification and vendor shall furnish the same, along with his
offer. Vendors whose current supply does not cover valves of all sizes, materials and ratings
(cryogenic test and reference list) required by MR, should confirm/ furnish the following for
consideration of their offer:
i).
Evidence of having conducted successfully at least one cryogenic test as per BS 6364.
Test certificate and reference list shall be furnished with the offer.
ii).
Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the
remaining valves not later than 12 weeks from the date of purchase order.
Offers of vendors who do not comply with above requirements would be rejected.
Cryogenic test need not be conducted for every order. Test conducted previously, which need
not be against GAIL order, is sufficient.
2.1
Cryogenic Test
Vendors to furnish copies of cryogenic test certificate for tests conducted as per details given
below:
i).
Shall be as per BS: 6364.
ii).
Test temperature, unless specifically called for otherwise in the individual MR, shall
be -45C for LTCS and -196C for all grades of austenitic stainless steel.
iii).
Tests carried out on a particular size of one type of valve, pressure rating and material
shall qualify all sizes equal to and below the test valve size for the same type, pressure
GAIL (INDIA) LTD

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TECHNICAL NOTES
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S 05 02 002
Page - 15 -of 17
rating and material. In case of austenitic SS any one grade would qualify for all other
grades of austenitic SS.
iv).
2.2
Tests shall have to be witnessed and certified by any one of the following third party
inspection agencies; M/s Lloyd, By, DNV, TUV or GAIL.
Reference List
Vendor shall furnish reference list for valves supplied for cryogenic service indicating the
name of client, year of supply. size, material, pressure rating, type of valve and quantity.
2.3
Post Order Testing Procedure

i).
ii).
Before conducting post order testing, vendor shall submit the following for approval:
a).
Test procedure (as per BS 6364).
b).
Cross-section drawing of the valve with material of construction.
c).
Schematic of test rig (as per BS 6364) with complete details.
Test has to be conducted on largest size of order for each type of valve and for each
material and class rating. Vendor shall offer one, two or three valves for selection of
test valve by inspector depending upon whether quantity of largest valve in the order
is one, two or three and more than three respectively.
In the event of failure of the test valve to meet the specification requirements, the
vendor shall conduct test on two more valves. If the other two valves which pass test
successfully are of lower size, then the qualification will be valid only to sizes up to which test has been conducted successfully.
iii).
In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the

test(s) conducted after receipt of order, the owner reserves the right to invoke any of
the provisions of the purchase order including cancellation of the purchase order at the
risk and cost of vendor,
3.0
Bonnet extension, wherever specified in the valve sheet to BS:6364 shall be for non cold
box application unless otherwise specified in the MR. Even if not called for in valve sheet,
valves indicated as LT or CRYO shall be supplied with bonnet extension.
4.0
Bonnet and Gland extension joints shall be of butt welded construction.
GAIL (INDIA) LTD

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TECHNICAL NOTES
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Page - 16 -of 17
5.0
Repair welding procedure for austenitic stainless steel valves in CRYO service shall have
to be qualified for impact test as per ASME B31.3. Minimum acceptable impact energy shall
he 20 J or lateral expansion of 0.38 mm at temperature of -1960C
6.0
Wherever impact test of SS studs / nuts is called for in the data sheet, the impact value shall
be 27 J at the intended service temperature specified in the data sheets.
GAIL (INDIA) LTD

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TECHNICAL NOTES
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Page - 17 -of 17
GAIL (INDIA) LTD

NEW DELHI
DATASHEET FORMAT
DATSHEET FOR TORQUE VALUES OF MOV
REV-0
Page 1 of 1
TECHNICAL NOTES
FOR
BUTT WELDED, SOCKET WELDED
AND SCREWED FITTINGS
GAIL (INDIA) LTD

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TECHNICAL NOTES FOR BUTT WELDED,

SOCKET WELDED AND SCREWED
FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 1 of 7
1.0
GENERAL
1.1
Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment
and marking shall conform to the applicable latest codes / standards / specifications as
specified in the material requisition (MR). Any deviation shall be highlighted on a separate
sheet by the vendor in the quotation itself.
1.2
Test reports shall be supplied for all mandatory tests as per the material specifications. Test
reports shall also be furnished for any supplementary tests as specified in the MR, Clauses
1.7.8, 1.9, 1.10 & 1.11. Material test certificates (physical properties, chemical composition
& heat treatment report) shall also be furnished for fittings supplied.
1.3
All fittings shall be seamless in construction unless otherwise specified. If fittings are
specified as welded, the same shall conform to Clause 1.7. Seamless fittings can be supplied
in place of welded fitting but with maximum negative tolerance of 0.3mm (max.) on wall
thickness. Welded fittings shall not be acceptable in place of seamless fittings.
1.4
Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings
shall be in accordance with ASME B36.10 and ASME B36.19 as applicable.
1.5
For reducing butt weld fittings having different wall thicknesses at each end, the greater
wall thickness of the fitting shall be employed and inside bore at each end shall be matched
with the specified inside diameter.
1.6
Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as
follows:
Material
Wall Thickness
Carbon Steel (Except Low Upto 22 mm

Temp. Carbon Steel)
> 22 mm
Alloy Steel, Stainless Steel
& Low Temp. Carbon
Steel
1.7
Wall Contour
Figure 2 Type A
Figure 3 Type A
Upto 10 mm
Figure 4
> 10 mm & Upto 25 mm
Figure 5 Type A
>25 mm
Figure 6 Type A
Welded Fittings:
1.7. 1 All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm.
Welds shall be ground smooth at least 25 mm from the ends.
1.7.2
For fittings made out of welded pipe, the welded pipe shall be double welded type & shall
be manufactured with the addition of filler metal.
1.7.3
Welded tees shall not be of fabricated (stub-in) type.

GAIL (INDIA) LTD
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FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 2 of 7
1.7.4
All welded fittings shall be normalised & 100% radiographed by X-ray on all welds made
by fitting manufacturers & also on the parent materials.
1.7.5
Welded pipes employed for manufacture of fittings shall be made by automatic welding
only.
1.7.6
All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative
tolerance of 0.3 mm.
1.7.7
Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after
weld repairs.
1.7.8
Irrespective of the material code requirement, all welded fittings indicated in the MR as
Cryo& LT shall meet impact test requirements of ASME B31.3. The impact test
temperature shall be -196 0C & -45 0C for stainless steel & carbon steel respectively unless
specifically mentioned otherwise in the MR.
1.8
Stainless Steel Fittings:
1.8.1
All stainless steel fittings shall be supplied in solution heat treated condition.
1.8.2
Solution annealing for stainless steel fittings shall be carried out again after weld repairs.
1.8.3
For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted
as per the following:
ASTM A 262 Practice B with acceptance criteria of 60 mils/year (max.).
Or
ASTM A 262 Practice E with acceptance criteria of no cracks as observed from 20X
magnification & microscopic structure to be observed from 250X- magnification
1 .8.4 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (e.g. SS309, 310,316,316H etc.) ASTM A 262 Practice C with
acceptance criteria of 15 mils/year shall have to be conducted.
1.8.5
For the IGC test as described in Clauses 1.8.3 & 1.8.4, two sets of samples shall be drawn
from each solution treatment lot, one set corresponding to the highest carbon content and
other set to the highest fitting thickness. When testing is conducted as per ASTM A 262
Practice E, photograph of microscopic structure shall be submitted for record.
1.9
Fittings under NACE category shall meet the requirements of MR-01-75.
1.10
Thickness I schedule lower or higher than specified shall not be accepted.
1.11
The gasket contact surfaces of stub ends shall be flat with face finish specified in the
requisition. Interpretation on the specified face finish is as follows:
GAIL (INDIA) LTD

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FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 3 of 7
Serrated Finish
Serrations with 250 to 500 in AARH
Smooth Finish/125 AARH
1.12
Seamless stub ends shall not have any welds on the body.
1.13
Galvanized fittings shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.
14
Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B1.20.1 upto
1.5 NB & IS 554 from 2 to 6 NB.
1.15
Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in
accordance with ASME B16.11 to the extent covered in the specification except for unions
which shall be in accordance with MSS-SP-83.
1.16
Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME,
MSS-SP & GAIL Standards shall be as per manufacturers standards. Contours of these
fittings shall meet the requirements of ASME B31.3. Manufacturer shall submit drawings /
catalogues of these items along with the offer.
1.17
Length of all long half couplings shall be 100 mm unless otherwise specified in the MR.
1.18
All seamless pipes employed for manufacturing of fittings shall be required to have
undergone hydro test to ASTM A 530. Welded pipes employed for manufacture of fittings
shall be tested as given below:
1.19
Welded Pipe Employed For Manufacture of Welded Fittings.
Test Criteria
ASTM A671 Gr. C65,70 (C1.32)

ASTM A672 Gr. C60,65,70 (Cl. 12, 22)
ASTM A671 Gr. CF6O,65,70,66 (Cl.32)
ASTM A691 Gr. Cr, 1Cr, 1%Cr, 2ACr, 5Cr, 9Cr (Cl.42)
P = 2ST/ D
S = 90% of SMYS.
T Nom. Wall Thickness
D = O.D. of Pipe.
API5L
ASTM A358 TP 304, 304L, 304H, 318, 318L, 318H, 321, 347
(Cl. 1, 3, 4)
P= 2ST/D
S = 85% of SMYS.
T = Nom. Wall Thickness
D = O.D. of Pipe.
ASTM B725
ASTM B725
ASTM B517
ASTM B517
ASTM B514
ASTM B514
The bevel ends of all butt weld fittings shall undergo 100% MP/ DP test.
GAIL (INDIA) LTD

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FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 4 of 7
1.20
Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable in forging

materials (upto 1) and wrought fitting materials (above 1) also in the corresponding
material grades.
1.21
Abbreviations for ends of swages and nipples shall be as follows:

PBE
TBE
TOE
TSE
TLE
:
:
:
:
:
Plain Both Ends

Threaded Both Ends
Threaded One End
Threaded Small End
Threaded Large End
2.0
IBR REQUIREMENTS
2.1
IBR Documentation Required:
2.1.1
Fittings under the purview of IBR (Indian Boiler Regulations) shall be accompanied with
original IBR certificate in Form Ill-C duly approved and countersigned by IBR authority /
local authority empowered by 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.
2.1.2
For materials 1Cr - Mo (ASTM A234 Gr.WP11 & ASTM A234 Gr.WP11W) & 2Cr 1Mo (ASTM A234 Gr.WP22 & ASTM A234 Gr.WP22W), where fittings are manufactured
from pipe, Form III-C approved by IBR shall include the tabulation of Et, Sc, & Sr values for
the entire temperature range given below. Et, Sc, & Sr values shall be such that throughout
the temperature range
SA: Allowable stress at the working metal temperature.

Et: Yield point (0.2% proof stress at the working metal temperature)
Sc: The average stress to produce elongation of 1% (creep) in 100000 hrs at the working
metal temperature.
Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature
and in no case more than 1.33 times the lowest stress to produce rupture at this
temperature.
GAIL (INDIA) LTD

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FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 5 of 7
Note: SA values given above are from ASME B31.3-1996. Values shall be as per the latest edition
prevailing.
2.2
For carbon steel fittings described IBR chemical composition shall conform to the
following:
Carbon (max)
0.25 %
Others (S, P, Mn)
As prescribed in IBR regulations
The above composition is not valid for Non-IBR fittings.

3.0
3.1
Each fitting shall be legibly and conspicuously stamped in accordance with the requirements
of applicable standards along with special condition like IBR, Cryo, NACE etc.
3.2
Steel die marking with round bottom punch may be permitted on body of butt weld CS &
lower alloy steel fittings, but for SS & higher alloy steel fittings, the same should be marked
by electro-etching only.
3.3
Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc,
Lead or Copper which causes corrosive attack on heating.
3.4
Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.
3.5
Fittings shall be protected from rust, corrosion and mechanical damage during
3.6
Rust preventive used on machined surfaces to be welded shall be easily removable with a
3.7
Fittings under IBR, Cryo, NACE shall be painted in red, light purple and canary
yellow stripes respectively for easy identification. Width of the stripe shall be 25 mm.
3.8
Each end of fitting shall be protected with a wood, metal or plastic cover.
GAIL (INDIA) LTD

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FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 6 of 7
3.9
Each size of fitting shall be supplied in separate packaging marked with the purchase order
number, item code number, material specification, size and schedule / thickness/ rating.
GAIL (INDIA) LTD

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FITTINGS
TECHNICAL NOTES
S-05-02-003
REV-0
Page 7 of 7
TECHNICAL NOTES
FOR
FLANGES, SPECTACLE BLINDS
AND DRIP RINGS
GAIL (INDIA) LTD

NEW DELHI
TECHNICAL NOTES FOR FLANGES,

SPECTACLE BLINDS AND DRIP RINGS
TECHNICAL NOTES
S-05-02-004
REV- 0
Page 1 of 5
1.0
GENERAL
1.1
All items, their dimensions, tolerances, chemical composition, physical properties, heat
treatment and testing etc. shall conform to the latest codes and standards specified in the
requisition. Deviations, if any, shall be clearly highlighted on a separate sheet by the vendor
in the quotation itself.
1.2
Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the requisition & Clauses 1.11, 1.12 & 1.15.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the flanges supplied.
1.2.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the Specification for Positive Material Identification (PMI) at Vendors Works.
1.3
Ends of weld neck flanges shall be bevelled to suit the schedule / thickness of matching pipe,
as specified in the requisition.
1.4
Bevel end details for welding neck flanges shall be as per ASME B 16.25. Contour of bevel
end shall be as follows:
1.5
Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and
schedule/ thickness of matching pipe.
1.6
Bore of slip on flanges shall suit the outside diameter of matching pipe.
1.7
Flange face finish shall be normally specified in the requisition as serrated finish, 125 AARH
etc. The interpretation for range of face finish shall be as follows:
Stock Finish
Serrated Finish/125 AARH
63 AARH
GAIL (INDIA) LTD

NEW DELHI
:
:
:
1000 in AARH max.

32 TO 63 in AARH

TECHNICAL NOTES
S-05-02-004
REV- 0
Page 2 of 5
1.8
Galvanised flanges shall be coated with zinc by hot dip process conforming to IS 4736/
ASTM A153.
1.9
Ends of screwed flanges unless otherwise specified shall have taper threads as per ASME/
ANSI B1.20.1 (upto 1.5 NB) and IS 554 (for 2 to 6 NB).
1.10 For ring joint flanges, blinds and spacers the hardness shall be as follows:
1.11 For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.
1.12 Flanges, blinds, drip rings under NACE category shall meet the requirements given in MR01-75 unless otherwise specified.
1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition.
1.14
I.G.C. Test for Stainless Steels:
1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges inter-granular
corrosion test shall have to be conducted as per following:
ASTM A262 Practice B with acceptance criteria of 60 mils/year (max.).
OR
ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20X
magnification & Microscopic structure to be observed from 250X magnification
1.14.2 When specifically asked for in requisition for high temperature application of some grades
of austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice C with
acceptance criteria of 15 mils/year shall have to be conducted. When testing is conducted
as per Practice E, photograph of microscopic structure shall be submitted for record.
1.14.3 For the IGC test as described in 1.15.1 & 1.15.2 two sets of samples shall be drawn from
each solution treatment lot; one set corresponding to highest carbon content and the other
corresponding to the highest rating / thickness.
1.15
All types of 321 or 347 stainless steel flanges shall be in a stabilised heat treated condition.
Stabilising heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilising heat treatment shall be 900C and 4
hours respectively.
GAIL (INDIA) LTD
NEW DELHI

TECHNICAL NOTES
S-05-02-004
REV- 0
Page 3 of 5
1.16
AWWA C207 flanges shall be hub type.
2.0
IBR REQUIREMENTS
2.1
IBR Documentation:
2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied
with 1BR Certificate original in Form III C duly approved and countersigned by IBR
authority / local authority empowered by Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
2.2
For carbon steel flanges described as IBR, chemical composition shall conform to the
following:
Carbon (max.)
0.25%
Others (S, P, Mn)
As prescribed in IBR Regulation
The chemical composition as indicated in this clause is not applicable for flanges other than
IBR.
3.0
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
3.1
Method of Manufacture
3.1.1 All carbon steel flanges having wall thickness 9.53 mm and above shall be normalised. The
normalising heat treatment shall be a separate heat treatment operation and not a part of the
hot forming operation.
3.1.2 All alloy steel (Cr-Mo) flanges shall be normalised and tempered. The normalising and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation.
3.2
Impact Test
3.2.1 For all carbon steels and alloy steels with wall thickness over 19 mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-I per heat of material and per heat treating batch. Impact test specimen shall be in
accordance with ASTM A370. Impact energies at 0 C shall average greater than 27J (20 ftlb) per set of 3 specimens, with a minimum of 19J (15 ft-lb).
4.0
4.1
All items shall be legibly and conspicuously stamped in accordance with the requirements of
applicable ASME, API and MSS Standards. In addition, GAIL item code, purchase order
number & special conditions like IBR, CRYO, NACE H2 etc. shall also be
stamped.
GAIL (INDIA) LTD

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TECHNICAL NOTES
S-05-02-004
REV- 0
Page 4 of 5
4.2
All items coming under the purview of IBR, CRYO , NACE & H2(hydrogen) shall
be painted in red stripes, light purple stripes, canary yellow stripes & sea green stripes (25
mm width) respectively for easy identification.
4.3
Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
or copper which cause corrosive attack on heating.
4.4
All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.
4.5
All items shall be protected from rust, corrosion and mechanical damage during
4.6
Rust preventive on machined surfaces to be welded shall be easily removable with a

4.7
Each end of flange shall he protected with the following materials:

Flange face
Bevelled end
Threaded end
Socket welding end
:
:
:
:
Wood, metal or plastic cover

Wood, metal or plastic cover
Plastic plug
Plastic cover or plug
4.8
Each size of flanges, blinds, etc. shall be supplied in separate packagings marked with the
purchase order number, item code number, material specification, size and rating.
5.0
ATTACHMENTS
Specification for Positive Material Identification (PMI) at Vendors Works S-14-02-001
GAIL (INDIA) LTD

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TECHNICAL NOTES
S-05-02-004
REV- 0
Page 5 of 5
TECHNICAL NOTES
FOR
BOLTS AND NUTS
(PIPING)
GAIL (INDIA) LTD

NEW DELHI
TECHNICAL NOTES FOR BOLTS AND

NUTS
TECHNICAL NOTES
S-05-02-005
REV-0
Page 1 of 3
TECHNICAL NOTES FOR BOLTS AND NUTS
1.
The process of manufacture, heat treatment, chemical and mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws and nuts shall be in accordance with the
codes/standards and specifications given in the requisition. Deviation (s), if any, shall be
clearly highlighted in the quotation. The applicable identification symbol in accordance
with the material specification shall be stamped on each bolt and nut.
2.
a.
Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
b.
Material test certificate shall also be furnished. (Heat Analysis, Product Analysis
and Mechanical Requirement)
3.
All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jack screws and ANSI B
18.2.2 for nuts.
4.
Threads shall be unified (UNC for 1 dia and 8UN for > 1 dia) as per ANSI B. 1.12 with
class 2A fit for studs, M/c bolts and jack screws and class 2B fit for nuts.
5.
Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length tolerance
shall be in accordance with the requirement of table F2 of Annexure-F of ANSI B 16.5.
6.
The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made
by the hot forged process and stamped as per respective material specification.
7.
Heads of jack screws and m/c bolts shall be heavy hexagonal type. Jack screw end shall be
rounded.
8.
Each size of studs & m/c bolts with nuts and jack screws shall be supplied in separate
containers marked with size and material specifications. CRYO shall be marked
additionally in case CRYO is specified in the requisition.
9.
All items shall be inspected and approved (stagewise) by GAIL inspector or any other
agency authorised by GAIL.
10.
The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
11.
All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed
condition unless specified otherwise in the material specification.
12.
Any additional requirements specified in the requisition shall be fully complied with.
13.
Stud bolts, m/c bolts, nuts & jack screws shall be impact tested wherever specified in the
material specification and also where the material specification is indicated as CRYO.
For S.S. nuts and bolts minimum impact energy absorption shall be 27 Joules and test
temperature shall be -196.0C unless mentioned otherwise in code. For other materials
impact energy and test shall be as per respective code.
GAIL (INDIA) LTD
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NUTS
TECHNICAL NOTES
S-05-02-005
REV-0
Page 2 of 3
14.
Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested as

per supplementary requirement S3 of ASTM A193.
15.
When specified as galvanised, the studs, m/c bolts and nuts shall be hot dip zinc coated in
accordance with requirements of class C of ASTM A153.
GAIL (INDIA) LTD

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NUTS
TECHNICAL NOTES
S-05-02-005
REV-0
Page 3 of 3
TECHNICAL NOTES
FOR
GASKETS
GAIL (INDIA) LTD

NEW DELHI
TECHNICAL NOTES FOR GASKETS
TECHNICAL NOTES
S-05-02-006
REV- 0
Page 1 of 3
1.0
GENERAL
1.1
All gaskets shall conform to the codes/standards and specifications given in the
requisition. Vendor shall strictly comply with MR/PR stipulations and no deviations
shall be permitted
1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall
be in accordance with the requirements of the manufacturers standards.
1.3 Testing
1.3.1
Test reports shall be supplied for all mandatory tests for gaskets as per the
standards specified in the requisition.
1.3.2
Chemical composition and hardness of RTJ gaskets shall also be furnished in

the form of test reports on samples.
1.3.3
For Spiral wound material following shall be furnished:

a.
Manufaturers test certificate for filler material and spiral material as

per the relevant material specifications.
b.
Manufacturers test certificate for raw materials and tests for

compressibility/ seal-ability & recovery as per the relevant material
specifications.
1.3.4
PMI shall be performed as per the scope and procedures defined in the
Specification for PMI at Vendors works for ring type joint gaskets.
1.3.5
Refer Inspection and Test Plan for Gaskets.
1.4
Full face gaskets shall have bolt holes punched out.
1.5
Filler material for spiral wound gaskets shall not have any color or dye.
1.6
All spiral wound gaskets shall be supplied with outer ring. Material of outer ring
shall be CS unless otherwise specified in the MR.
1.7
For spiral wound gaskets, material of Inner Compression ring shall be same as
spiral strip material. In addition to the requirements as per code and as specified in
the MR, inner ring shall be provided for the following:
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1.8
a.
Sizes 26 and above
b.
Class 900 and above
Hardness of metallic RTJ gaskets shall not exceed the values specified below unless
otherwise specified in MR:
Ring Gasket Material
Maximum Hardness (BHN)
Soft Iron
90
Carbon Steel
120
5 Cr., Mo
130
Type 304, 316, 321, 347
140
Type 304L, 316L
120
1.9
Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.
1.10
Gaskets of different types and sizes shall be placed in separate shipping containers
and each container clearly marked with the size, rating, material specification and
item code.
1.11 All items shall be inspected and approved by GAIL Inspector or any other agency
authorized by GAIL.
1.12 Any additional requirements specified
with.
in the requisition, shall be fully complied
1.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B 16.5
up to 24 (except 22 size) and to ASME B 16.47 B above 24 unless specified
otherwise. For 22 size, the matching flange standard shall be MSS-SP44 unless
specified otherwise.
1.14 Spiral wound gasket as per ASME B 16.20 shall match flanges to ASME B 16.5 up to
24 (except 22 size) and to ASME B 16.47 B above 24 unless specifically
mentioned otherwise. For 22 size, the matching flange standard shall be MSS-SP44
unless specified otherwise.
1.15 Abbreviation
(I)
(O)
CAF
GRAFIL
:
:
:
:
GAIL (INDIA) LTD

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Inner Ring
Outer Ring
Compressed Asbestos Fibre
Grafoil Filler
TECHNICAL NOTES
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FOR
FABRICATION AND ERECTION OF
PIPING
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FABRICATION AND ERECTION OF PIPING
SPECIFICATION
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Page 1 of 16
Abbreviations:
PMI
Positive Material Identification
NDT
P&ID :
Process and Instrumentation Diagram
A.S.
Alloy Steel
C.S.
Carbon Steel
C.I.
Cast Iron
S.S.
Stainless Steel
LTCS :
Low Temperature Carbon Steel
NACE :
National Association of Corrosion Engineers
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CONTENTS
Sl. No.
Description
1.
SCOPE
2.
SCOPE OF WORK OF CONTRACTOR
3.
BASIS OF WORK
4.
FABRICATION
5.
ERECTION
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1.0
SCOPE
This specification covers general requirements of fabrication and erection of above
ground and trench piping systems at site. The specification covers the scope of work
of contractor, basis of work to be carried out by contractor and standards,
specifications and normal practice to be followed during fabrication and erection by
the contractor.
2.0
SCOPE OF WORK OF CONTRACTOR

Generally the scope of work of contractor shall include the following:
2.1
Transportation of required piping materials (as described in Cl.2.l.1), pipe support

(material as described in Cl. 2.3) and all other necessary piping materials from
Owners storage point or contractors storage point (in case of contractors scope of
supply) to work site/ shop including raising store requisitions for issue of materials in
the prescribed format & maintaining an account of the materials received from
Owners stores.
2.1.1 Piping materials include the following but not limited to the same.
2.2
a.
Pipes (All sizes and schedule)
b.
Flanges (All sizes, types & Pressure ratings).
c.
Fittings (All sizes, types and schedule)
d.
Valves (All sizes, types and Ratings)
e.
Gaskets (All sizes, types & Ratings)
f.
Bolts, Nuts or M/C Bolts (All types)
g.
Expansion Joint/Bellows (All types)
h.
Specialty items like online filters, ejectors, sample coolers, steam traps,
strainers, air traps etc.
i.
Online instruments like control valve, orifice flange, rotameter, safety valves
etc.
Shop & field fabrication and erection of piping in accordance with documents listed
under C1.3.0 i.e. BASIS OF WORK including erection of all piping materials
enumerated above.
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2.3
Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors,
clips, cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts,
teeposts including erection of spring supports and sway braces.
2.4
2.4.1 Fabrication of piping specials like special radius bends, reducers, miters etc.
2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3 Fabrication of swage nipples as and when required.
2.4.4 Fabrication of odd angle elbow like 60, 30 or any other angle from 90/45 elbows as
and when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when
required.
2.4.6 Fabrication of stub-in connection with or without reinforcement.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/
different thickness wherever required.
2.5
Modifications like providing additional cleats, extension of stem of valve, locking

arrangement of valves etc. as and when required.
2.6
Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines upto
2- within the unit battery limit and get subsequent approval from Engineer-inCharge as and when called for.
2.7
Obtaining approval for drawings prepared by contractor from statutory authority, if

required.
2.8
Spun concrete lining of the inside of pipes 3 NB & above including fittings and flanges
as required in accordance with specification.
2.9
Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required
in specification.
2.11 Performing PMI using alloy analysers as per Standard Specification for Positive
Material Identification at Construction Sites.
2.12 Casting of concrete pedestals and fabrication & erection of small structures for pipe
supports including supply of necessary materials.
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2.13 Providing insert plates from concrete structures and repair of platform gratings around
pipe openings.
2.14 Making material reconciliation statement and return of Owners supply left over
materials to Owners storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection,
flushing and testing of piping systems.
2.16 Pickling (as and when applicable) as per standard specification for chemical cleaning
of C.S. suction piping of compressors.
2.17 Submission of job execution procedure as per standard specification for review and
approval of Engineer-in-charge covering all above activities.
3.0
BASIS FOR WORK
3.1
The complete piping work shall be carried out in accordance with the following
3.1.1 Approved for Construction drawings and sketches issued by GAIL to the Contractor Plans and/ or Isometrics.
3.1.2 Approved for Construction drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
3.1.3 Approved Process licensors standards and specifications.
3.1.4 Drawings, sketches and documents prepared by contractor duly approved by
Engineer-in- Charge (such as isometrics of small bore piping and offsite piping etc.)
3.1.5 Approved construction job procedures prepared by Contractor as stipulated in 2.16
3.1.6 GAIL specifications/documents as below:
a.
Process and Instrument Diagram.
b.
Piping Materials Specification
c.
Piping support standards.
d.
Line list
e.
Piping support indices (only in offsite), if supports are not shown in plan.
f.
Standard specification of Non-destructive Requirement of Piping
g.
Welding specification charts for piping classes
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h.
Standard Specification for Pressure Testing of Erected Piping System
i.
Welding specification for fabrication of piping
j.
Any other GAIL or OTHER specifications attached with Piping Material

Specification or special condition of contract (such as standard for cement lining
of pipe, standard of jacketed piping, standard for steam tracing, Dimensional
Tolerances etc.)
k.
Procedure for storage, preservation and positive identification of materials at

Contractors works / stores.
3.1.7 Following codes, standards and regulations

a.
ASME B 31.3
Process Piping
b.
ASME Sec. VIII
Code for unfired pressure vessel.
c.
IBR Regulations
d.
IS: 823
Code for procedure for Manual Metal Arc welding

of Mild Steel (for structural steel).
e.
NACE Std.
Code for Sour Services material requirements

MR-0 1-75
Note: All codes referred shall be latest edition, at the time of award of contract.
3.2
Deviations
Where a deviation from the Basis of Work and approved job procedure described
above is required or where the basis of work does not cover a particular situation, the
matter shall be brought to the notice of Engineer - in - Charge and the work carried
out only after obtaining
4.0
FABRICATION
4.1
Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping
system shall be strictly as per the Piping Material Specification for the Pipe Class
specified for that system. To ensure the above requirement, all piping material
supplied by the Owner / Contractor shall have proper identification marks as per
relevant standards / GAIL specifications/ Licensors specification. Contractor shall
provide identification marks on left over pipe lengths wherever marked up pipe lengths
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have been fabricated I erected. Material traceability is to be maintained for AS., SS.,
NACE, LTCS, material for Hydrogen service and other exotic materials by way of
transferring heat number, etc. (hard punching) as per approved procedure. This shall
be in addition to colour coding for all piping materials to avoid mix-up.
For the purpose of common understanding the construction job procedure, to be
submitted by the contractor, shall include proposal for
- Maximizing prefabrication, inspection and testing at fabrication shop with minimum
field joints.
- Positive material identification, handling, storage & preservation.
4.2
Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per GAIL Standard. The
Contractor shall be responsible for working to the dimensions shown on the drawings.
However, the Contractor shall bear in mind that there may be variations between the
dimensions shown in the drawing and those actually existing at site due to minor
variations in the location of equipments, inserts, structures etc. To take care of these
variations Field Welds shall be provided during piping fabrication. An extra pipe
length of 100 mm over and above the dimensions indicated in the drawing may be left
on one side of the pipe at each of the field welds. During erection, the pipe end with
extra length at each field weld shall be cut to obtain the actual dimension occurring at
site. Isometrics, if supplied may have the field welds marked on them. However, it is
the responsibility of the Contractor to provide adequate number of field welds. In any
case no extra claims will be entertained from the Contractor on this account. Wherever
errors I omissions occur in drawings and Bills of Materials it shall be the Contractors
responsibility to notify the Engineer-in-Charge prior to fabrication or erection.
4.3
IBR Piping
4.3.1 Contractor shall be supplied generally with all drawings for steam piping falling under
the purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The
Contractor shall carry out the fabrications, erection and testing of this piping as per
requirements of Indian Boiler Regulations and to the entire satisfaction of the local
Boiler Inspector. The Contractor shall also get the approval of IBR inspector for all
fabrication and testing done by him at his own cost. All certificates of approval shall be
in proper JBR forms.
4.3.2 Approval of boiler inspector on the drawings prepared by the contractor shall be
obtained by the contractor at his own cost.
4.4
Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In
general, joining of lines 2 and above in process and utility piping shall be
accomplished by butt-welds. Joining of lines 1-1/2 and below shall be by socket
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welding/butt welding/threaded joints as specified in Piping Material Specifications.

However, in piping 1-1/2 and below where socket welding/ threaded joints are
specified butt - welds may be used with the approval of Engineer-in-Charge for pipe to
pipe joining in long runs of piping. This is only applicable for non-galvanized piping
without lining.
Flange joints shall be used at connections to Vessels, Equipments, Valves and where
required for ease of erection and maintenance as indicated in drawings.
4.5
Butt Welded and Socket Welded Piping

End preparation, alignment and fit-up of pipe pieces to be welded, welding, preheating, post-heating and heat treatment shall be as described in the welding
specification and NDT specification.
4.6
Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.l NPT as
required to match threads on fittings, valves etc. All other piping shall have threads as
per ANSI B2.l, tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be
reamed. Threading of pipes shall be done preferably after bending, forging or heat
treating operations. If this is not possible, threads shall be gauge checked and chased
after welding heat treatment etc.
During assembly of threaded joints, all threads of pipes and fittings shall be
thoroughly cleaned of cuttings, dirt, oil or any other foreign matter. The male threads
shall be coated with thread sealant and the joint tightened sufficiently for the threads
to seize and give a leak proof joint.
Threaded joints to be seal-welded shall be cleaned of all foreign matter, including
sealant and made up to full thread engagement before seal welding.
4.7
Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different
orientation is shown in the drawing.
Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws
in the flange, shall be done before welding it to the pipe.
4.8
Branch Connections
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer
welding specifications. Templates shall be used wherever required to ensure accurate
cutting and proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using
forged tees the rates quoted for piping shall be inclusive of this work.
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Reinforcement pads shall be provided wherever indicated in drawings/ specifications

etc.
4.9
Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not
be used.
Cold bends for lines 1-1/2 and below, with a bend radius of 5 times the nominal
diameter shall be used as required in place of elbows wherever allowed by piping
specifications. Bending of pipes 2 and above may be required in some cases like that
for headers around heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles,
bulges, flat spots and other serious defects. They shall be true to dimensions. The
flattening of a bend, as measured by the difference between the maximum and
minimum diameters at any cross-section, shall not exceed 8% and 3% of the nominal
outside diameter, for internal and external pressure respectively.
4.10 Forging and forming

Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2 and
below, shall be as per ASME B 31.3.
4.11 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabricated reducers shall be
governed by the Piping Material Specifications. Generally all 90 deg. mitres shall be 4piece 3-weld type and 45 deg. mitres shall be 3-piece 2-weld type as per GAIL
Standard unless otherwise specified. Reducers shall be fabricated as per directions of
Engineer-in-Charge. The radiographic requirements shall be as per Material
Specifications for process and utility systems and NDT Specification for steam piping
under IBR, radiographic requirements of IBR shall be complied with.
4.12 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed /
edge prepared wherever required to meet fabrication and erection requirements, as
per drawings and instructions of Engineer-in-Charge. Nipples as required shall be
prepared from straight length piping.
4.13 Galvanized Piping
Galvanized carbon steel piping shall be completely cold worked, so as not to damage
galvanized surfaces. This piping involves only threaded joints and additional external
threading on pipes may be required to be done as per requirement.
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4.14 Jacketed Piping

The Jacketing shall be done in accordance with GAIL Specification or Licensors
specification as suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be
accomplished at shop by Contractor. Position of jump over and nozzles on the jacket
pipes, fittings etc. shall be marked according to pipe disposition and those shall be
prefabricated to avoid damaging of inner pipe and obstruction of jacket space.
However, valves, flow glasses, in line instruments or even fittings shall be supplied as
jacketed.
4.15 Shop Fabrication / Pre-Fabrication
The purpose of shop fabrication or pre-fabricationm is to minimise work during
erection to the extent possible. Piping spool, after fabrication, shall be stacked with
proper identification marks, so as facilitate their withdrawal at any time during
erection. During this period all flange (gasket contact faces) and threads shall be
adequately fabricated by coating with a removable rust preventive. Care shall also be
taken to avoid any physical damage to flange faces and threads.
4.16 Miscellaneous
4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample
cooler, supporting elements like turn buckles, extension of spindles and interlocking
arrangement of valves, operating platforms as required by Engineer-in-Charge.
4.16.2 Spun Concrete Lining
The work of inside spun concrete lining of pipes and specials of diameter 3 and above
shall be done as per material specifications and special condition contract.
4.16.3 Fabrication of pipes from plate
Pipes shall be fabricated at site as and when required as per the specifications
attached and the actual Piping Material Specification.
5.0
ERECTION
5.1
Cleaning of Piping before Erection

Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned
inside and outside by suitable means. The cleaning process shall include removal of all
foreign matter such as scale, sand, weld spatter chips etc. by wire brushes, cleaning
tools etc. and blowing with compressed air/or flushing out with water. Special cleaning
requirements for some services, if any shall be as specified in the piping material
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specification or isometric or line list. SS jacketed piping requiring pickling shall be

pickled to remove oxidation and discolouring due to welding.
5.2
Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without
the consent of Engineer-in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the
drawings shall be strictly followed as these clearances may be required for the free
expansion of piping / equipment. No deviations from these clearances shall be
permissible without the approval of Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall
be brought to the notice of Engineer-in-Charge and corrective action shall be taken as
per his instructions.
5.3
Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as
indicated in the drawing. Confirmation in writing shall be obtained by the Contractor
from the Engineer-in-Charge, certifying that the gap between the pipes is as indicated
in the drawing, before drawing the cold pull. Stress relieving shall be performed before
removing the gadgets for cold pulling.
5.4
Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the
Contractor. Corrective action shall be taken by the Contractor in consultation with
Engineer- in-Charge wherever the Contractor is not able to maintain the specified
slope.
5.5
Expansion Joints/ Bellows

Installation of Expansion Joints/Bellows shall be as follows:
5.5.1 All Expansion joints / Bellows shall be installed in accordance with the specification
and Installation drawings, supplied to the Contractor.
5.5.2 a.
Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from
the Case (s) and check for any damage occured during transit.
b.
The Contractor shall bring to the notice of the Engineer-in- Charge any damage
done to the bellows / corrugations, hinges, tie-rods, flanges / weld ends etc.
c.
Each Expansion Joint / Bellow shall be blown free of dust! foreign matter with
compressed air or cleaned with a piece of cloth.
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5.5.3
5.5.4
a.
For handling and installation of Expansion Joints, great care shall be taken
while aligning. An Expansion Joints shall never be slinged from bellows
corrugations / external shrouds, tie / rods, angles.
b.
An Expansion Joints / Bellow shall preferably be slinged from the end pipes/
flanges or on the middle pipe.
a.
All Expansion Joints shall be delivered to the Contractor at Installation length,

maintained by means of shipping rods, angles welded to the flanges or weld
ends or by wooden or metallic stops.
b.
Expansion Joints stop blocks shall be carefully removed after hydrostatic

testing. Angles welded to the flanges or weld ends shall be trimmed by saw as
per manufacturers instructions and the flanges or weld ends shall be ground
smooth.
5.5.5 a.
b.
The pipe ends in which the Expansion Joint is to be installed shall be perfectly
aligned or shall have specified lateral deflection as noted on the relevant
drawings.
The pipe ends/ Flanges shall be spaced at a distance specified in the drawings.
5.5.6 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall
be tack welded/ bolted. The mating pipes shall again be checked for correct
alignment.
5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged
Expansion Joint, the mating flanges shall be bolted.
5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes
and Expansion Joints are in correct alignment and that the pipes are well supported
and guided.
5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall
maintain parallelism of restraining rings or bellows convolutions.
5.5.10 Precautions
a.
For carrying out welding, earthing lead shall not be attached with the Expansion
Joint.
b.
The Expansion bellow shall be protected from arc weld spot and welding
spatter.
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c.
5.6
Hydrostatic Testing of the system having Expansion Joint shall be performed

with shipping lugs in position. These lugs shall be removed after testing and
certification is over.
Flange Connections
While fitting up mating flanges, care shall be exercised to properly align the pipes and
to check the flanges for trueness, so that faces of the flanges can be pulled together,
without inducing any stresses in the pipes and the equipment nozzles. Extra care shall
be taken for flange connections to pumps, turbines, compressors, cold boxes, air
coolers etc. The flange connections to these equipments shall be checked for
misalignment, excessive gap etc. after the final alignment of the equipment is over.
The joint shall be made up after obtaining approval of Engineer-in-Charge.
Temporary protective covers shall be retained on all flange connections of pumps,
turbines, compressors and other similar equipments, until the piping is finally
connected, so as to avoid any foreign material from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between
these flange faces is uniformly compressed. To achieve this, the bolts shall be
tightened in a proper sequence. All bolts shall extend completely through their nuts
but not more than 1/4.
Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts
uniformly after bringing flange flush with gaskets with accurate pattern and lateral
alignment.
5.7
Vents and Drains

High point vents and low point drains shall be provided as per the instructions of
Engineer- in-Charge, even if these are not shown in the drawings. The details of vents
and drains shall be as per piping material specifications / job standards.
5.8
Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the
layout drawings. In case of any difficulty in doing this or if the spindle orientation /
position is not shown in the drawings, the Engineer-in-Charge shall be consulted and
work done as per his instructions. Care shall be exercised to ensure that globe valves,
check valves, and other uni-directional valves are installed with the Flow direction
arrow on the valve body pointing in the correct direction. If the direction of the arrow
is not marked on such valves, this shall be done in the presence of Engineer-in-Charge
before installation.
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Fabrication of stem extensions, locking arrangements and interlocking arrangements

of valves (if called for), shall be carried out as per drawings/ instructions of Engineerin- Charge.
5.9
Instruments
Installation of in-line instruments such as restriction orifices, control valves, safety
valves, relief valves, rotameters, orifice flange assembly, venturimeters, flowmeters
etc. shall form a part of piping erection work.
Fabrication and erection of piping upto first block valve / nozzle / flange for installation
of offline Instruments for measurement of level, pressure, temperature, flow etc. shall
also form part of piping construction work. The limits of piping and instrumentation
work will be shown in drawings / standards / specifications. Orientations / locations of
take-offs for temperature, pressure, flow, level connections etc. shown in drawings
shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above
and the precautions to be taken are covered in flushing, testing and inspection of
piping (GAIL Stds). Care shall be exercised and adequate precautions taken to avoid
damage and entry foreign matter into instruments during transportation, installation,
testing etc.
5.10 Line Mounted Equipments / Items

Installation of line mounted items like filters, strainers,, steam traps, air traps,
desuperheaters, ejectors, samples coolers, mixers, flame arrestors, sight glasses etc.
including their supporting arrangements shall form part of piping erection work.
5.11 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless
otherwise specified in piping classes) all bolts and nuts during storage, after erection
and wherever flange connections are broken and made-up for any purpose
whatsoever. The grease and graphite powder shall be supplied by the Contractor
within the rates for piping work.
5.12 Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal
effects of the piping system and to prevent its vibrations. Location and design of pipe
supports will be shown in drawings for lines 3 NB & above for line below 3 NB
Contractor shall locate and design pipe supports in line with GAIL Stds. and obtain
approval of Engineer - in - Charge on drawings prepared by Contractor, before
erection. However, any extra supports desired by Engineer-in-Charge shall also be
installed.
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Page 15 of 16
No pipe shoe I cradle shall be offset unless specifically shown in the drawings.
Hanger rods shall be installed inclined in a direction opposite to the direction in which
the pipe moves during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and
insulation is over. Springs shall be checked for the range of movement and adjusted if
necessary to obtain the correct positioning in cold condition. These shall be
subsequently adjusted to hot setting in operating condition. The following points shall
be checked after installation, with the Engineer-in-Charge and necessary confirmation
in writing obtained certifying that:
- All restraints have been installed correctly.
- Clearances have been maintained as per support drawings.
- Insulation does not restrict thermal expansion.
- All temporary tack welds provided during erection have been fully removed.
- All welded supports have been fully welded.
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SPECIFICATION
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FOR
NON DESTRUCTIVE EXAMINATION OF
PIPING
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STANDARD SPECIFICATION OF
NON-DESTRUCTIVE
EXAMINATION OF PIPING
SPECIFICATION
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Page 1 of 16
Abbreviation :DP/LP :
Dye Liquid Panetrant
MP
Magnetic Particle
CS
Carbon Steel
AS
Alloy Steel
SS
Stainless Steel
ASTM :
American Society for Testing & Materials
ASME :
IBR
Indian Boiler Regulations
PM
Piping Material Specification
ASNT :
American Society of Non-Destructive Testing
PCN :
Personal Certification in Non-Destructive Testing
PWHT:
Post Weld Heat Treatment
UST
Ultrasonic Testing
HS&E :
Safety, Health & Environment
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CONTENTS
SL. No.
TITLE
1.
GENERAL
2.
VISUAL EXAMINATION
3.
NON DESTRUCTIVE EXAMINATIONS
4.
TABLE I
5.
ULTASONIC WELD EXAMINATION
6.
INSPECTION
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1.
GENERAL
1.1
SCOPE
The specification covers the General Requirements for Non- Destructive
Examinations of shop and field fabricated piping.
1.2
RELATED CODES AND ENGINEERING STANDARDS

Referred codes/ standards are as follows. Latest edition of following codes/standard
shall be followed :
a.
b.
c.
d.
e.
f.
g.
h.
1.3
ASME Boiler and Pressure Vessels codes, Section V & VIII (Div.-1) including
Addenda
ASME B 31.3
ANSI B 31.8
ASME B16.5
ASME B 16.34
PCN/ ASNT
PMS
In addition to that all general specification dealing with welding and fabrication of
various equipment shall apply.
CONFLICT
Where a conflict occurs between this Specification and any of the above Codes or
standards the more stringent shall apply. The CONTRACTOR shall inform the
OWNER in writing and receive written certification form the OWNER/ CONSULTANT.
The CONTRACTOR shall have readily available for use at the request of the
OWNER, latest editions of all codes, specification and standards necessary for
execution of the work at work site.
1.4
NDE COMPANY CERTIFICATION

All Non Destructive Examination (NDE) Contractors contracted by the OWNER or
working for fabricators or Contractors carrying out work on the OWNER behalf shall
have in place an up-to-date Quality Control Manual and Code of Practice which shall
cover the following:
i)
All aspects of NDE of which the CONTRACTOR, SUB-CON TRACTOR is

qualified.
ii)
Current resumes of all presently employed personnel including their

certifications (PCN, ASNT, CGSB or equivalent).
iii)
All proposed specific NDE procedure,
A registered copy of QC manual shall be made available to OWNER and shall be

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reviewed and approved by the OWNER quality assurance personnel prior to

services being used. Updates to the Manual shall be forwarded to the registered
holder as they become available.
The OWNER will review and approve element's i), ii) & iii) above: prior to start on
any said company work. Any approval given by the OWNER does not relieve the
CONTRACTOR of his obligations under governing, codes, rules and specifications.
All equipment shall be certified and current, to recognized calibration standard and
in first class working condition.
Full compliance with all governmental and local regulatory requirements of HS&E
which shall be fully complied with.
2.0
VISUAL INSPECTION
Visual examination shall be carried out before, during and after fabrication in
accordance with ASME Sec. V article 9 and ASME B31.3. Cracks, (regardless of size
and location) and under cutting or any evidence of poor workmanship, materials,
etc., if not repairable shall be cause for rejection.
Welds shall be visually inspected wherever accessible in accordance with the
following requirements:
1
2
3
4
5
Internal misalignment
Cracks or lack of fusion Incomplete
penetration (for
Incomplete penetration (for other than
100% Radiography butt-weld)
Surface porosity and exposed slag

inclusions
(4.7mm.
Nom
Wall
thickness and less)
Concave root surface (SLICK UP)
6
7
8
9
10
Weld ripples irregularities

Lack of uniformity in bead width
Lack of uniformity of leg length
Unevenness of Bead
11
Overlap
Weld Undercutting
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1.5 MM or Less
None permitted.
Depth shall not exceed the lesser of
0.8 MM or 0.2 times thickness of
thinner component joined by butt-weld.
The total length of such imperfections
shall not exceed 38 MM in any 150 MM
of weld length.
Not permitted
For single sided welded joints
concavity of the root surface shall not
reduce the total thickness of joint
including reinforcement to less than the
thickness of the thinner of the
components being joined.
2.5 MM or Less
2.5 MM or Less
2.5 MM or Less
2.0 MM or Less
0.8 MM or 1/4 thickness of thinner
components joined by butt weld,
whichever is less. (shall be smooth
finished)
1.5 mm or less
NON-DESTRUCTIVE
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12
13
Bead Deflection
2.5 mm or less
External weld reinforcement and internal weld protrusion (when backing rings
are not used) shall be fused with and shall merge smoothly into the component
surfaces. The height of the lesser projection of external weld reinforcement or
internal weld protrusion from the adjacent base material surface shall not
exceed the following limits :
Wall thickness of thinner component Weld reinforcement or internal weld
joined by butt weld (MM)
protrusion (MM) Max
6.4 and under

Over 6.4 12.7
Over 12.7 25.4
Over 25.4
14
15
1.6
3.2
4.0
4.8
Throat thickness of fillet welds:

Nominal thickness of the thinner component x 0.7 or more.
Flattening:
Flattening of a bend, as measured by difference between the nominal outside
diameter and minimum or maximum diameter at any cross section shall not
exceed 5% of the nominal outside diameter of pipe.
16
Reduction of Wall Thickness:

Reduction of wall thickness of a bend, as measured by difference between the
nominal thickness and minimum thickness shall not exceed 10% of the nominal
wall thickness of pipe.
Welds having any imperfections which exceed the limitations specified in
various clauses shall be repaired by welding, grinding or overlaying etc.
Welds having any of imperfections which exceed the limitations specified in various
clauses of 2.1 shall be repaired by welding, grinding, overlaying etc.
However number of times of repair welding for the same weld shall be as follows:
MATERIAL
NO. OF TIMES OF REPAIR WELDING
1.0
2.0
CS UP TO 300#
CS ABOVE 300#
3.
NON DESTRUCTIVE EXAMINATION
3.1
The type and extent of Weld Examination shall be in accordance with Table-1. All
visual and supplementary methods of girth weld examination shall be in accordance
with ASME B31.3 & the requirements of this standard specification.
3.2
Welds between dissimilar material shall be examined by method & to the extent
required for the material having the more stringent examination.
3.3
Following categories of critical piping are classified under inspection Class IV (100
% radiography):
a)
b)
c)
3 OR LESS
2 OR LESS
High Pressure
Severe Cyclic
Low Temperature
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:
:
:
Classes 900# & above

As defined by ASME B 31.3
Below temperature of -45 Deg C.
NON-DESTRUCTIVE
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3.4
3.5
3.5
d)
Critical Service
e)
f)
High alloys
High Temperature
:
:
Hydrogen,
Oxygen,
NACE,
Caustic,
Chlorine & such other critical services.
5 Cr. & above for all pressure classes
Above 500 Deg.C
EXTENT OF INSPECTION AND TESTING

a)
Piping systems which are designed and constructed in accordance with ASME
Standard B 31.3, Chemical Plant and Petroleum Refinery Piping, shall be
radiographed as per Table - I.
b)
Piping systems which are designed and constructed in accordance with ASME
B31.8 standard for gas pipeline systems shall have all welds radiographically
inspected for 100%,
c)
Hardness testing shall be carried out of welds on vessels and piping in sour
or corrosive service and 10% of local PWHT weld as per ASTM Specification
E 10, ANSI 1331.3.
The CONTRACTOR shall prepare and maintain documentation to track percentage

of welds tested and the weld repair rate. The proposed documentation shall be
made available for review and approval.
CONTRACTOR shall not deviate from any requirement of this specification
without written approval to do so from OWNER
3.6
No exemption permitted in regards to full HS&E compliance.
3.7
Open drains vents or other open ended line shall be leak tested only.
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4.
TABLE-I (with applicable Notes)
TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION

INSPECTION CLASS: I
IN
SP
N.
CL
AS
S
SERVICE
CATEGO
RY D
FLUID
SERVICE
MATERIA
L (NOTE3)
CARBON
STEEL
AUSTENE
TIC SS
HDPE
CUPRO
NICKEL
TEMP
DEG C
PRESS
CL.
B16.5/
B16.34
0-186
(-) 29
TO 86
(-) 20
TO 50
(-) 29
TO 60
150 #
UP TO
10.55
KG/
2
CM
PIPING
CLASS
A3A,
A3Y,
J2A, J3A,
J5A,
A4Y,
A5Y
A3K
A1Z,
A4Z, A5Z
TYPE
OF
EXAM.
TYPE OF WELD EXAMINATION
GIR
TH
BUT
T
WEL
D
SCK
T
WEL
D
(NO
TE2)
ATTA
CHME
NT
WELD
FAB.
BRNC
H
WELD
(NOTE
1)
FAB
MITR
/ RED
a)
VISUAL
100
%
100
%
100%
100%
100%
b) LP
(NOTE 4,
6, 9)
---
---
---
10%
10%
REMARKS FOR ABOVE TABLE:

1.
LP TEST NOT APPLICABLE TO NON-METALLIC CLASSES
2.
MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
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TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)

INSPECTION CLASS: II
IN
SP
N.
CL
AS
S
II
SERVICE
a) ALL
SERVICES
COVERED
UNDER
INSPECTION
CLASS-I BUT
EXCEEDING
CATEGORYD PR./TEMP.
LIMITATION.
b) ALL
SERVICES
EXCEPT
COVERED
UNDER
CLASS I
BUT NONTOXIC, NOT
SUBJECTED
TO SEVERE
CYCLIC
CONDITIONS
MATE
RIAL
(NOTE
-3)
TEM
P
DEG
C
PRESS
CL.
B16.5/
B16.34
-29
TO
400
CS
150 #
UP TO
10.55
KG/
2
CM
CS
(IBR)
PIPING
CLASS
A1A,
A6A,
A7A,
A8A,
A9A,
A11A,
A13A,
A15A,
A20A,
A32A,
A33A,
A33Y
A2A
TYPE OF
EXAM.
a) VISUAL
b)
RADIOGRAP
HY (NOTE 5,
6)
c) MP/LP/
(NOTE 4,6,
10,11)
d)
HARDNESS
GIR
TH
BUT
T
WEL
D
SOC
KT
WEL
D
(NO
TE2)
ATTA
CHME
NT
WELD
FAB.
BRNC
H
WELD
(NOTE
I)
FAB
.MIT
R/
RED
100
%
100
%
100%
100%
100%
10%
---
---
---
50%
---
10%
---
10%
50%
NO
TE7
NO
TE7
NOTE7
NOTE7
NOTE
-7

1.
FOR A2A IBR SERVICE NOTE-8 IS ALSO APPLICABLE
2.
FOR A33A & A33Y FIRE WATER SERVICE, NOTE-12 IS ALSO APPLICABLE.
3.
EXTENT OF HARDNESS TEST FOR A11A IS 100%.
4.
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TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)

INSPECTION CLASS: III
IN
SP
N.
CL
AS
S
III
SERVICE
a) TOXIC,
NONLETHAL &
FLAMMAB
LE
b)
FLAMMAB
LE / NON
FLAMMAB
L & TOXIC
/ NONTOXIC;
NOT
SUBJECT
TO SEVERE
CYCLIC
CONDITIO
NS
ALL
GENERAL
SERVICES
EXCEPT
THOSE
SUBJECT
TO SEVERE
CYCLIC
CONDITIO
NS.
MATE
RIAL
(NOTE
-3)
CS
TEM
P
DEG
C
ABO
VE
(-)29
PRES
S CL.
B16.5/
B16.3
4
PIPING
CLASS
TYPE OF
EXAM.
GIRTH
BUTT
WELD
SCK
T
WEL
D
(NO
TE 2)
ATTA
CHME
NT
WELD
FAB.
BRNC
H
WELD
(NOTE
1)
FAB
MITR
/ RED
100%
100
%
100%
100%
100%
20%
---
---
---
100%
c) MP/LP/
(NOTE 4,6,
11)
---
20%
---
20%
---
d)
HARDNES
S
NOTE7
NOTE
NOTE7
NOTE7
NOTE
-7
150 #
--a) VISUAL
KILLED
CARBO
N
STEEL
CARBO
N
(-) 45
TO
204
150#
TO
600#
A4A,
B4A,
D4A
b)
RADIOGR
APHY
(NOTE 5,
6)
(-) 29
TO
427
300#
TO
600#
STEEL
CS
(IBR)
B1A,
B6A,
B9A,
B13A,
B32A,
D1A
-7
B2A,
D2A

1.
FOR IBR SERVICE B2A & D2A NOTE-8 IS ALSO APPLICABLE
2.
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5.
ULTRASONIC WELD EXAMINATION

Ultrasonic Operators
Ultrasonic operators supplied by the NDE CONTRACTOR shall be certified to a
General Standards Board (ASNT/PCN) approved by the OWNER.
UT testing shall be carried out :
(i) As per ASME B31.3 and ASME Sec. V article 5.
(ii) All category 'D' welds which are not being radio graphed and all other welds
configuration, which does not permit to be radio graphed, shall be ultrasonic tested.
(iii) All tie-in welds where pressure testing are not possible.
(iv) Ultrasonic testing, in lieu of radiography, is acceptable only where radiography
is not practicable e.g. branch connections
6.
INSPECTION
The CONTRACTOR shall extend all facilities, assistance and co-operate fully with the
OWNER in all aspects of inspection and NDE and shall give adequate notice of any
required fabrication inspection stages, together with sufficient time for thorough
inspection by the OWNER. OWNER shall have the right to establish hold points at
any point in the fabrication sequence.
Records and evidence of all weld
examinations shall be available at all times for OWNER to review and approve.
OWNER may use any method of inspection necessary to establish quality control
and ensure adherence to welding procedures. OWNER shall have the right to accept
or reject any weld not meeting the requirements of this specification.
.
CONTRACTOR shall intimate sufficiently in advance the commencement of
qualification test, welding works and acceptance tests to enable the owner/ owners
representative to be present to supervise them. Any discrepancies between the
approved WPS and the production welds noted by OWNER, any or all of the work
made under these conditions is subject to rejection.
Applicable Notes to Table-I

1.
Branch weld shall consist of the Welds between the pipe & reinforcing element (if
any), nozzles & reinforcing element and the pipe & nozzle under the reinforcing
element. Reinforcing element to be interpreted as pads, saddles, weldolets,
sockolets etc.
2.
Seal welds of threaded joints shall be given the same examination as socket welds.
3.
Unless specifically stated, all materials shall be for Non-IBR service.

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4.
5.
Magnetic particle & the Liquid penetrant method of examination shall be in

accordance with section-V of the ASME Boiler and Pressure Vessels Code, Article VII
and VI respectively. The entire area of the accessible finished weld surface shall be
examined. Selected root runs, subject to a maximum of 10%, before finished weld,
may also be examined, at the discretion of the engineer-in-charge.
a)
Wherever MP/LP testing is specified, either MP or LP test may be used. But

wherever only MP test is specified, LP method of examination may be used
only if MP examination is impractible in the field as concurred by GAIL sitein-charge.
b)
Random 10% of LP/MP test shall mean testing, by applicable test, one
weld for each ten welds or less made by the same welding procedure or
operator or both. Similarly Random 20% shall mean testing, by applicable
test, one weld for each five welds or less made by the same welding
procedure or operator or both.
c)
When Liquid Penetrant examination is specified, the surface shall be free of

peened discontinuities. Abrasive blast cleaning shall be followed by light
surface grinding prior to liquid penetrant examination.
d)
Inspection shall be performed in the welds excluding those for which

radiography has been done.
e)
Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni stell
shall be Liquid Penetrant tested only when welded with austenitic material
where MP test has been specified.
Radiography
General
o X - Ray is the preferred radiographic method. Use of Gamma ray for
examination is not permitted. Particular attention shall be paid to
using radiographic ultra fine grain film suitable for the application,
maintaining correct radiographic geometry during exposure, obtaining
correct density also required by the appropriate standard and the
correct placement and exposure of image quality indicators (IQI's or
penetrameters).
o ASTM wire type IQI's are preferred. GAIL may permit the use of ASTM
hole type IQI's on a pre-approved basis, provided the NDT
CONTRACTOR can demonstrate satisfactory results.
o Radiographic technique shall produce maximum contrast and good
definition of IQI wires. The inability to view the appropriate wire or
hole on any radiograph shall be cause for automatic rejection of that
radiograph which shall be re- radiographed at no expense to GAIL
o Operator Certification
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a)
6.
Radiographers supplied by the CONTRACTOR shall be certified to

ASNT Level II, AWS QC] and as per AWS B1.10 (guide for nondestructive inspection of welds). An operator qualified to ASNT Level I
may assist the Level II operator but all film and sentencing
interpretation shall be carried out by a Level ll or higher operator who
shall sign off all report sheets. Visual welding inspection shall be
conducted only by a qualified welding inspector, who shall have a
minimum AWS (QC. I) CWI or CSWIP 3.1 certification. GAIL shall
review and approve all QA/QC personnel prior to deployment on the
project.
Random 10% or 20% radiography shall mean examination not less than
one from each 10 welds or less in case of Random 10% radiography or one
from each five welds or less in case of Random 20% radiography made by
the same welding procedure or Welder or both. Irrespective of percentage,
no. of welds to be radiographed shall be minimum 1. However first two
welds made by each welder shall also be radiographed in case of Random
radiography. Welds selected for examination shall not include flange welds
and shall be radiographed for their entire length. However, where it is
impossible or impracticable to examine the entire weld length of field welds
for either random or 100% radiography, and if the same impossibility is
agreeable to GAIL site-in-charge, then a single 120 Deg. Exposure of the
weld length may be given a Magnetic Particle test or Liquid Penetrant test.
However in such case for ferro-magnetic materials, only MP test shall be
acceptable for classes higher than 600#.
b)
In-process examination shall not be substituted for any required radiographic

examination.
c)
Number of radiographs per one circumferential weld shall be as per ASME

Sec. V Article 2 and 22.
When radiography or other non-destructive inspection is specified, acceptance

criteria for repairs or defects shall be as follows:
a)
In case of 100% examination, any unacceptable weld shall be repaired and

reinspected.
b)
If required random examination reveals a defect requiring repair, then:

b.1
Two additional examination of the same type shall be made of the

same kind of item (if welded joint, then by the same welding
procedure or operator or both).
b.2
If the group of items examined as required by b.1 above is

acceptable, the item requiring repair shall be repaired or replaced and
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reexamined as required and all items represented by this additional

examination shall be accepted.
b.3
If any of the items examined as required by b.1 above reveals a

defect requiring repair, two further comparable items shall be
examined for each defective item found by examination.
b.4
If all the items examined as required by b.3 are acceptable, the items
requiring repair shall be repaired or replaced and reexamined as
required, and all items represented by this further examination shall
be acceptable.
b.5
Number of times repair welding could b done for the same weld
before acceptance shall be as follows:
Material
No. of times repair welding is allowed
C.S. upto 300#

C.S. above 300#
Killed Steel
Low alloy steel
Austenitic S.S.
3.5 Ni Steel
Al & Al base alloy
Cu & Cu base Alloy
Others
3
2
2
2
2
2
2
2
2
less
less
less
less
less
less
less
less
less
b.6
Welds not found acceptable for allowed number of times of repair as

per b.5 above shall be replaced and reexamined.
b.7
If any of the items examined as required by b.4 above reveals a

defect requiring repair, all items represented by these examination
shall be either:
7.
or
or
or
or
or
or
or
or
or
repaired or replaced and reexamined as required.

Fully examined and repaired or replaced as necessary, and
reexamined as necessary.
Hardness Test:
a)
Hardness test shall be in accordance with ASTM specification E10. Hardness

tests of the heat affected zone shall be made at a point as near as
practicable to the edge of the weld. One test per weld shall be performed.
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b)
Hardness test where specifically called out in Table-I of this specification or

in PMS, shall be carried out irrespective of thickness and to the extent
(%age) as mentioned therein.
c)
All welds which are given heat treatment shall be hardness tested. Hardness
test shall be performed after final heat treatment.
d)
A minimum of 10% of Welds of hot formed and hot bent materials in each
heat treatment batch which are furnace heat treated and 100% of those
which are locally heat treated, shall be hardness tested.
e)
For C-0.5 Mo steels, a minimum of 10% of welds shall be hardness tested.
f)
Hardness test requirement not covered in b) & e) above shall be as per

ASME B 31.3.
g)
The hardness limit applies to the weld and heat affected zone. Following
hardness values shall be maintained:
BASE METAL GROUP

CS
CS (NACE)
Cr 0.5% or less
Cr 0.5% & up to 2%
Cr 2.25% & up to 10%
18/8 SS (NACE)
8.
MAXIMUM HARDNESS (BHN/ RC)

238BHN/ RC22
200 BHN
225 BHN
225 BHN
241 BHN
RC 22
For IBR service lines, following IBR requirements shall apply in addition to the notes
4, 5, 6, 7, 12 and Table-I. In case of conflict between above notes and these
requirements , the more stringent ones shall apply. IBR Piping shall be erected of
IBR inspector approved material and construction procedure. Erected piping shall
be hydrotested, inspected and approved by IBR inspector.
a)
Piping over 102 mm (4) bore:

10% of welds made by each welder on a pipeline with a minimum of two
welds per welder, selected at random, shall be subjected to radiography.
b)
Piping 102 mm (40 bore and under, but not less than 38 mm (1-1/2) bore:
2% of welds made by each welder on a pipeline with a minimum of one weld
per welder, selected at random, shall be subjected to radiography or may be
cut for visual examination and tests.
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NON-DESTRUCTIVE
SPECIFICATION
S 05 02 012
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Page 15 of 16
c)
Piping less than 38 mm (1.5) bore:

Special tests are not normally required but 2% of weldfs by each welder on a
pipe line may be cut out from the pipeline for the visual examination and
bend tests.
d)
Retests:
If any test specification is unsatisfactory, two further weld specimens for
retests shall be selected from the production welds and subjected to tests. In
the event of failure of any retest specimens, the production welds carried out
by this welder subsequent to the previous test shall be given special
consideration.
9.
For fabricated fittings LP test shall be done on the final pass of welding only, in
addition to visual examination.
10.
For mitres and fabricated reducers, LP/ MP test shall be done on root pass in
addition to radiography applicable to circumferential joint of respective piping class.
11.
For branch connections, LP/ MP test shall be done on root pass and final pass.
12.
10% of the butt weld joints shall be radiographed, however 50% of these butt weld
joints shall be field weld joints.
13.
For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.
14.
DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR

a)
Electrode and welding consumables qualification records for the welding
consumables tested and approved for the work.
b)
Batch test certificate, for the electrodes used, obtained from the Electrode
Manufacturers.
c)
Proposed heat treatment chart procedure.
d)
Heat treatment chart.
e)
Weld joint tensile, hardness test, Impact test result.
f)
Welding procedure specification immediately after receipt of order.
g)
Welding procedure qualification records.
h)
Welder performance qualification records immediately after conducting
welder qualification tests.
i)
Radiography procedure.
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NON-DESTRUCTIVE
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FOR
INSPECTION, FLUSHING AND TESTING
OF PIPING SYSTEMS
GAIL (INDIA) LTD.

NEW DELHI
S TANDARD SPECIFICATION FOR

INSPECTION, FLUSHING & TESTING
OF PIPING SYSTEMS
SPECIFICATION
S 05 02 013
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Page 1 of 10
CONTENTS
Sl. No.
Description
1.
SCOPE
2.
INSPECTION
3.
FLUSHING
4.
TESTING
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OF PIPING SYSTEMS
SPECIFICATION
S 05 02 013
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Page 2 of 10
Abbreviations
PMI
Positive Material Identification
ppm
parts per million
S.S.
Stainless Steel
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OF PIPING SYSTEMS
SPECIFICATION
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Page 3 of 10
1.0
SCOPE
This specification covers the general requirements for inspection, flushing and
testing of piping systems. However testing of steam lines falling under IBR shall
also be governed by Indian Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-InCharge.
2.0
INSPECTION
During various stages and after completion of fabrication and erection, the piping
system shall be inspected by the Engineer-In-Charge to ensure that:
-
Proper piping material has been used.
PMI has been performed as per Standard Specification for Positive Material
Identification at Construction Sites, S-14-02-001.
Piping has been erected as per drawings and instructions of Engineer-InCharge.
All supports have been installed correctly.
3.0
Test preparations mentioned in this specification have been carried out.
FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by fresh potable water or dry compressed air, wherever
water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign
material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility
water pressure. For air flushing, the line / system will be pressurised by
compressed air at the required pressure which shall be 50 psi maximum. The
pressure shall then be released by quick opening of a valve, already in line or
installed temporarily for this purpose. This procedure shall be repeated as many
times as required till the inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and
other instruments like thermowells which may interfere with flushing shall not be
included in flushing circuit.
The screens / meshes shall be removed from all permanent strainers before
flushing. Screens I meshes shall be reinstalled after flushing but before testing.
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During flushing temporary strainers shall be retained. These shall be removed,

cleaned and reinstalled after flushing but before testing.
In case an equipment such as column, vessel, exchanger etc. form part of a piping
circuit during flushing. This shall be done with the approval of Engineer-In-Charge.
However, equipments thus included in the circuit shall be completely drained and
dried with compressed air after flushing is completed.
During flushing discharged water/air shall be drained to the place directed by the
Engineer-In-Charge. If necessary, proper temporary drainage shall be provided by
the contractor.
Care shall be taken during flushing so as not to damage/spoil work of other
agencies. Precautions shall also be taken to prevent entry of water/foreign matter
into equipments, electric motors, instruments, electrical installations etc. in the
vicinity of lines being flushed.
The contractor shall carry out all the activities required before, during and after the
flushing operation, arising because of flushing requirements, such as but not
limited to the following:
Dropping of valves, specials, distance pieces, inline instruments and any other
piping part before flushing. The flanges to be disengaged for this purpose shall be
envisaged by the contractor and approved by the Engineer-In-Charge. These
flanges shall be provided with temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve distance pieces, piping specials
etc. shall be reinstalled by the contractor with permanent gaskets. However,
flanges at equipment nozzles and other places where isolation is required during
testing, only temporary gaskets shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each
piping system for the flushing done in the proforma provided/approved by the
Engineer-in-Charge.
4.0
TESTING
4.1
Extent of Testing
With the exclusion of instrumentation, piping systems fabricated or assembled in
the field shall be tested irrespective of whether or not they have been pressure
tested prior to site welding of fabrication.
To facilitate the testing of piping systems, vessels and other equipments may be
included in the system with the prior approval of Engineer-In-Charge if the test
pressure specified is equal to or less than that for the vessels and other
equipments.
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OF PIPING SYSTEMS
SPECIFICATION
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Pumps, compressors and other rotary equipments shall not be subjected to field
test pressure.
Lines which are directly open to atmosphere such as vents, drains, safety valves
discharge need not be tested, but all joints shall be visually inspected. Wherever
necessary, such lines shall be tested by continuous flow of fluid to eliminate the
possibility of blockade. However, such lines if provided with block valve shall be
pressure tested up to the first block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum
cold working pressure of the valve. Test pressure applied to valves shall not be
greater than the manufacturers recommendation nor less than that required by the
applicable code. Where allowable seat pressure is less than test pressure, test shall
be made through an open valve.
Instruments in the system to be tested, shall be excluded from the test by isolation
or removals, unless approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting and draining such as orifice plates
etc. shall not be installed unless testing is complete.
Control valves shall not be included in the test system. Where bypasses are
provided test shall be performed through the bypass and br necessary spool shall
be used in place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test
pressure shall not be installed until the system has been tested. Where piping
systems to be tested are directly connected at the battery limits to piping for which
the responsibility rests with other agencies, the piping to be tested shall be isolated
from such piping by physical disconnection such as valve or blinds.
4.2
General Requirements / Test Preparation for Testing

Testing shall be carried out with permanent gaskets installed unless specified
otherwise or instructed by the Engineer-in-Charge.
No pressure test shall be carried out against closed valve unless approved by the
Engineer-in-Charge.
The Engineer-in-Charge shall be notified in advance by the Contractor, of the
testing sequence and programme, to enable him to be present for witnessing the
test. The Contractor shall be fully responsible for making arrangements with the
local boiler inspector to witness the tests for steam lines falling under IBR. IBR
certificates for these tests shall be obtained in the relevant IBR forms and furnished
to the Engineer-in-Charge.
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SPECIFICATION
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Before testing, all piping shall be cleaned by flushing to make it free from dirt,
loose scale, debris and other loose foreign materials.
All piping systems to be hydrostatically tested shall be vented at the high points
and the systems purged of air before the test pressure is applied.
Wherever in the line any void exists due to any reasons, like absence of control
valves, safety valves, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during
the test. Before pressuring the lines, each weld joint shall be cleaned by wire brush
to free it from rust and any other foreign matter.
Where a system is to be isolated at a pair of companion flanges, a blank shall be
inserted between the companion flanges. Minimum thickness of the blank shall be
designed in accordance with applicable design code.
Open ends of piping system where blanks cannot be used, such as pumps,
compressors, turbines or wherever equipment or pipe spools have been recovered
or disconnected prior to hydrostatic testing, shall be blinded off by using standard
blind flanges of same rating as the piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest
point in the piping system to be tested, to avoid overstressing of any of the lower
portions of the system. For longer lines and vertical lines , two or more pressure
gauges shall be installed at locations decided by the Engineer-in-Charge.
For lines containing check valves any of the following alternatives shall be adopted
for pressure testing:
Whenever possible pressurize up-stream side of valve.
Replace the valve by a temporary spool and reinstall the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. At these flanges, temporary gaskets
shall be provided during testing and shall be replaced by permanent gaskets
subsequently.
For check valves in lines 1 and below flapper or seat shall be removed during
testing (if possible). After completion of testing the flapper! seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary
supports during testing as directed by the Engineer-in-Charge.
Piping which is spring or counter-weight supported shall be temporarily supported,
where the weight of the fluid would overload the support. Retaining pins for spring
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OF PIPING SYSTEMS
SPECIFICATION
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supports shall be removed only after testing is completed and test fluid is
completely drained.
When testing any piping system, air or steam of approximately 2 kg/cm2g may be
used as preliminary test to detect missing gaskets etc. as this avoids the necessity
of draining the line to make repairs. However, steam shall not be used for this
purpose, if the steam temperature is more than the design temperature of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where
the pipe is continuously jacketed, before it is jacketed. The outer jacket shall be
tested separately as a system. For piping with discontinuous jacketing the core pipe
and the jacket shall be tested as separate continuous systems.
4.3
Testing Media, Test Pressure and Test Pressure Gauges
4.3.1 Testing Media

In general all pressure test shall be hydrostatic using iron free water, which is clean
and free of silt. Maximum chlorine content in water for hydrostatic testing for S.S.
piping shall be 15-20 ppm.
Air shall be used for testing only if water would cause corrosion of the system or
overloading of supports etc. in special cases as directed by Engineer-in-Charge.
Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene,
methanol etc. shall be used as the testing medium, with due consideration to the
hazards involved. These test fluids shall be specified in the line list given to the
contractor.
4.3.2 Test Pressure
The hydrostatic! Pneumatic test pressure shall be as indicated in the line list or as
per the instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the
following:
Test pressure required as per line list.
Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress,
maximum length of piping shall be included in each test.
4.3.3 Test Pressure Gauge
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OF PIPING SYSTEMS
SPECIFICATION
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All gauges used for field testing shall have suitable range so that the test pressure
of the various systems falls in 40% to 80% of gauge scale range. Gauge shall be of
a good quality and in first class working condition.
Prior to the start of any test or periodically during the field test programme, all test
gauges shall be calibrated using a standard dead weight gauge tester or other
suitable approved testing apparatus. Any gauge showing an incorrect zero reading
or error of more than 2% of full scale range shall be discarded .The Engineer-inCharge shall check the accuracy of master pressure gauge used for calibration.
4.4
Testing Procedure
4.4.1 Hydrostatic Test

All vents and other connections used as vents shall be left open while filling the line
with test fluid for complete removal of air. In all lines for pressurising and
depressurising the system, temporary isolating valves shall be provided if valve
vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved by the
Engineer-incharge.
Pressure shall be applied by means of a suitable test pump or other pressure
source which shall be isolated from the system as soon as test pressure is reached
and stabilised in the system.
A pressure gauge shall be provided at the pump discharge for guidance in bringing
the system to the required pressure.
The pump shall be attended constantly during the test by an authorized person.
The pump shall be isolated from the system whenever the pump is to be left
unattended.
Test pressure shall be maintained for a sufficient length of time to permit thorough
inspection of all joints for leakage or signs of failure. Any joint found leaking during
a pressure test shall be retested to the specified pressure after repair. Test period
shall be maintained for a minimum of three hours.
The pump and the piping system to be tested are to be provided with separate
pressure indicating test gauges. These gauges are to be checked by the standard
test gauge before each pressure test.
Care shall be taken to avoid increase in the pressure due to temperature variation
during the test.
4.4.2 Air Test
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OF PIPING SYSTEMS
SPECIFICATION
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When testing with air, pressure shall be supplied by means of a compressor. The
compressor shall be portable type with a receiver, after cooler and oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution
so that the joints can be examined for leaks.
All other details shall be same as per hydrotesting procedure (specified above).
4.5
Completion of Testing
After the hydrostatic test has been completed, pressure shall be released in a
manner and at a rate so as not to endanger personnel or damage equipments.
All vents and drains shall be opened before the system is to be drained and shall
remain open till all draining is complete, so as to prevent formation of vacuum in
the system. After draining, lines / systems shall be dried by air.
After testing is completed the test blinds shall be removed and equipment / piping
isolated during testing shall be connected using the specified gaskets, bolts and
nuts. These connections shall be checked for tightness in subsequent pneumatic
tests to be carried out by the contractor for complete loop / circuit including
equipments (except rotary equipments).
Pressure test shall be considered complete only after approved by the Engineer-inCharge. Defects, if any, noticed during testing shall be rectified immediately and
retesting of the system / line shall be done by the contractor at his cost.
4.6
Test Records
Records in triplicate shall be prepared and submitted by the contractor for each
piping system, for the pressure test done in the proforma provided/approved by the
Engineer-in-Charge. Records shall also be submitted for the PMI undertaken as per
GAIL Std. Specification No. S-14-02-001
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10

SHOP & FIELD PAINTING
GAIL (INDIA) LTD

NEW DELHI

SHOP AND FIELD PAINTING
DOCUMENT NO.
S-05-02-014
REV-0
Page 1 of 49
CONTENTS
1.0
GENERAL
2.0
SCOPE
3.0
CODES & STANDRADS
4.0
EQUIPMENT
5.0
SURFACE PREPARATION
6.0
PAINT MATERIALS
7.0
PAINT SYSTEMS
7.1
PRE-ERECTION / PRE-FABRICATION AND SHOP PRIMING FOR CARBON

STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL
STRUCTURES, PIPING AND EQUIPMENT ETC.
7.2
REPAIR OF PRE-ERECTION / FABRICATION AND SHOP PRIMING AFTER

ERECTION / WELDING FOR CARBON STEEL, LOW TEMPERATURE CARBON
STEEL & LOW ALLOY STEELS, ITEMS IN ALL ENVIRONMENTS
8.0
FILED PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON

STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)
9.0
FILED PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL,

LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)
10.0
FILED PAINT SYSTEM FOR HIGHLY CORROSIVE ENVIRONMENT (FOR CARBON

STEEL & LOW ALLOY STEEL), EXTERNAL SURFACES OF UNINSULATED COLUMNS,
VESSELS,
HEAT
EXCHANGERS,
BLOWERS,
PIPING,
PUMPS,
TOWERS,
COMPRESSORS, FLARE LINES, STRUCTURAL STEEL ETC.

11.0
FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL
ENVIRONMENTS
12.0
FIELD PAINT SYSTEM FOR CARBON STEEL & LOW ALLOY STEEL STORAGE TANKS
(INTERNAL)
13.0
COATING SYSTEM FOR EXTERNAL SIDE OF UNDER GROUND CARBON STEEL

PLANT PIPING AND TANKS
14.0
PAINTING UNDER INSULATION (HOT, COLD & SAFETY) FOR CARBON STEEL, LOW
TEMPERATURE CARBON STEEL, STAINLESS STEEL PIPING AND EQUIPMENT IN
ALL ENVIRONMENT
15.0
INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF

COOLERS / CONDENSERS
16.0
FIELD PAINTING SYSTEM FOR GI TOWERS / NON-FERROUS TUBE SHEETS

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DOCUMENT NO.
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17.0
STORAGE
18.0
COLOUR CODE FOR PIPING
19.0
IDENTIFICATION OF VESSELS, PIPING ETC.
20.0
PAINTING FOR CIVIL DEFENCE EQUIPMENT
21.0
22.0
GUARANTEE
23.0
QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
24.0
PROCEDURE FOR APPROVAL OF NEW PAINT MANUFACTURERS

ANNEXURE I
LIST OF RECOMMENDED MANUFACTURERS
ANNEXURE II
LIST OF RECOMMENDED MANUFACTURERS PRODUCTS
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DOCUMENT NO.
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1.0
GENERAL
1.1
These technical specifications shall be applicable for the work covered by the
contract, and without prejudice to the various codes of practice, standard
specifications etc. It is understood that contractor shall complete the work in all
respects with the best quality of materials and workmanship and in accordance
with the best engineering practice and instructions of Engineer-in-charge.
1.2
Wherever it is stated in the specification that a specific Material is to be supplied or

a specific work is to be done, it shall be deemed that the same shall be supplied or
carried out by the contractor.
Any deviation from this standard without
written
appropriate authority will result in rejection of job.
2.0
deviation
permit
from
SCOPE
Scope of work covered in the specification shall include, but not limited to the
following.
2.1
This specification defines the requirements for surface preparation, selection and
application of paints on external surfaces of equipment, vessels, machinery,
piping, ducts, and steel structures, external & internal protection of storage tanks
for all services, RCC Chimney & MS Chimney with or without Refractory lining
and Flare lines etc.
2.2
Extent of Works
2.2.1 The following surfaces and materials shall require shop, pre-erection and field
painting :
a.
All un-insulated CS & AS equipment like columns, vessels, drums, storage

tanks, heat exchangers, pumps, compressors, electrical panels and motors
etc.
b.
All un-insulated carbon and low alloy piping fittings and valves (including
painting of identification marks), furnace, ducts and stacks.
c.
All items contained in a package unit as necessary.
d.
All structural steel work, pipe, structural steel supports, walkways, hand
rails, ladders, platforms etc .
e.
f.
RCC / MS chimneys with or without refractory lining & Flare lines.

Identification colour bands on all piping as required including insulated
aluminum clad, galvanized, SS and non-ferrous piping.
g.
Identification lettering / numbering on all painted surfaces of equipment /

piping insulated aluminum clad, galvanized, SS and non-ferrous piping.
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h.
Marking / identification signs on painted surfaces of equipment / piping

for Hazardous service.
i.
Supply of all primers, paints and all other materials required for painting
other than Owner's supply.
j.
Over insulation surface of equipments and pipes wherever required.
k.
Painting under insulation for carbon steel and stainless steel as specified.
l.
Repair work of damaged / pre-erection / fabrication shop primer and weld

joints at field.
2.2.2 The following surfaces and materials shall not be painted unless otherwise
specified:
a.
Un-insulated austenitic stainless steel.
b.
Plastic and / or plastic coated materials.
c.
2.3
Non ferrous materials like Aluminum, Galvanized "piping", "gratings" and

"Hand rails" etc. except G.I. Towers.
Documents
2.3.1 The contractor shall perform the work in accordance with the following
documents issued to him for execution of work.
a.
Bill of quantities for Piping, equipment, machinery and structures etc.
b.
Piping Line List.
c.
Painting specifications including special civil defense requirement.
2.4
Unless otherwise instructed final painting on pre-erection / shop primed pipes

and equipments shall be painted in the field, only after mechanical completion
and testing on system are completed, as well as, after completion of steam
purging wherever required.
2.5
Changes and deviations required for any specific job due to clients requirement
or otherwise shall be referred to GAIL for deviation permit.
3.0
CODES & STANDARDS
3.1
Without prejudice to the provision of Clause 1.1 above and the detailed
specifications of the contract, the following codes and standards shall be followed
for the work covered by this contract.
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DOCUMENT NO.
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3.2
IS-5
Colour coding
IS-101
Methods of test for ready mixed paints and enamels
IS-2379:1990
Indian Standard for Pipe line identification colour

Code
ASTM
American Standard test methods for paints and

coatings
ASA A 13.1-1981
Scheme for Identification of piping systems: American

National Standards Institution.
Surface Preparation Standards:

Following standards shall be followed for surface preparations:
3.2.1 Swedish Standard : SIS-05 5900-1967 / ISO-8501-1-1988

(Surface preparations standards for Painting Steel Surfaces).
This standard contains photographs of the various standards on four different
degrees of rusted steel and as such is preferable for inspection purpose by the
Engineer-in-Charge.
3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications
(SSPC SP)
3.2.3 British Standards (Surface Finish or Blast-cleaned for Painting) BS-4232.
3.2.4 National Association of Corrosion Engineers, U.S.A. (NACE)
3.2.5 Various International Standards equivalent to Swedish Standard for surface
preparation are given in Table-I.
3.3
The contractor shall arrange, at his own cost, to keep a set of latest edition of
any one of the above standards and codes at site.
3.4
The paint manufacturer's, instructions shall be followed as far as practicable at

all times. Particular attention shall be paid to the following:
a.
Instructions for storage to avoid exposure as well as extremes of temp.
b.
Surface preparation prior to painting.
c.
Mixing and thinning.
d.
Application of Paints and the recommended limit on time intervals

between coats.
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4.0
EQUIPMENT
4.1
All tools, brushes, rollers, spray guns, abrasive material, hand

cleaning and all equipments, scaffolding materials, shot / wet
water blasting equipments & air compressors etc. required to
suitable for the work and all in good order and shall be
contractor at site and in sufficient quantity.
4.2
Mechanical mixing shall be used for paint mixing operations in case of two pack
systems except that the Engineer-in-Charge may allow the hand mixing of small
quantities at his discretion.
5.0
SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR

AND DOCUMENTATION
5.1
General
/ power tools for

abrasive blasting,
be used shall be
arranged by the
5.1.1 In order to achieve the maximum durability, one or more of following methods of
surface preparation shall be followed, depending on condition of steel surface
and as instructed by Engineer-in-Charge. Adhesion of the paint film to surface
depends largely on the degree of cleanliness of the metal surface. Proper surface
preparation contributes more to the success of the paint protective system:
a.
Manual or hand tool cleaning
b.
Mechanical or power tool cleaning.
c.
Blast cleaning.
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure
that a clean and dry surface is obtained. The minimum acceptable standard in
case of manual or hand tool cleaning shall be St.2 or equivalent, in case of
mechanical or power tool cleaning it shall be St.3 or equivalent, in case of blast
cleaning it shall be Sa 2 or equivalent as per Swedish Standard SIS-0559001967 / ISO-8501-1-1988. Where highly corrosive conditions exist, blast
cleaning
shall be Sa3 as per Swedish Standard.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent
prior to surface cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces
undergoing such cleaning or during humid weather conditions having humidity
exceeding 85% .
5.1.4 Irrespective of the method of surface preparation, the first coat of primer must
be applied on dry surface. This should be done immediately and in any case
within 4 hours of cleaning of surface. However, at times of unfavorable weather
conditions, the Engineer-in-Charge shall have the liberty to control the time
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period, at his sole discretion and / or to insist on re-cleaning, as may be

required, before primer application is taken up. In general, during unfavorable
weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.5 The external surface of R. C .C. chimney to be painted shall be dry and clean.
Any loose particle of sand, cement, aggregate etc. shall be removed by
scrubbing with soft wire brush if necessary, acid etching with 10 - 15% HCL
solution for about 15 minutes shall be carried out and surface must be
thoroughly washed with water to remove acid & loose particles then dry
completely before application of paint.
5.2
Procedure of Surface Preparation
5.2.1 Blast Cleaning

5.2.1.1
Air Blast Cleaning
The surfaces shall be blast cleaned using one of the abrasives: Al2O3, particles
chilled cast iron or malleable iron and steel at pressure of 7 kg/cm2 at appropriate
distance and angle depending on nozzle size maintaining constant velocity and
pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or
grit of size not greater than 0.055" maximum in case of steel and malleable iron
and 0.04" maximum in case of chilled iron. Compressed air shall be free from
moisture and oil. The blasting nozzles should be Venturi style with tungsten
carbide or boron carbide as the materials for liners. Nozzles orifice may vary from
3/16" to 3/4". On completion of blasting operation, the blasted surface shall be
clean and free from any scale or rust and must show a grey white metallic lusture.
Primer or first coat of paint shall be applied within 4 hours of surface preparation.
Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal which is to be cleaned. Surface
profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50
microns). If possible vacuum collector shall be installed for collecting the
abrasives and recycling.
5.2.1.2
Water Blast cleaning
Environmental, health and safety problems associated with abrasive blast cleaning
limit the application of Air Blast Cleaning in many installations. In such case
water blast cleaning is resorted to.
Water Blast Cleaning can be applied with or without abrasive and high pressure
water blasting. The water used shall be inhibited with sodium chromate /
phosphate. The blast cleaned surface shall be washed thoroughly with detergents
and wiped with solvent and dried with compressed Air. For effective
cleaning,
abrasives are used. The most commonly used pressure
for high pressure
water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at
35-45 liters / minute water volume and pressures up to 10000 psi and water
volume of 45 liters / minute provide maximum cleaning.
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The water blast cleaned surface shall be comparable to SSPC-SP-12 / NACE

NO. 5. The operation shall be carried out as per SSPC guidelines for water
Blast cleaning. The indicative value for sand injection is as given below:
Air
300 to 400 Cu. ft / min.
Water
5- 10 liters/min. with corrosion inhibitor
Sand
200 - 400 lbs / hr.
Nozzle
0.5 to 1" dia
Special equipments for water blast cleaning with abrasives now available shall
be used.
5.2.2 Mechanical or Power tool cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping
hammers, grinding wheels or rotating steel wire-brushes. Excessive burnish of
surface shall be avoided as it can reduce paint adhesion. On completion of
cleaning, the detached rust mill scale etc. shall be removed by clean rags and /
or washed by water or steam and thoroughly dried with compressed air jet
before application of paint.
5.2.3 Manual or hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the
application of other surface preparation procedure and hence does not appear in
the specifications of paint systems.
Hand tool cleaning normally consists of the following:
a.
Hand de-scaling and / or hammering
b.
Hand scraping
c.
Hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed
by hammering, scrapping tools, emery paper cleaning, wire brushing or
combination of the above methods. On completion of cleaning, loose material
shall be removed from the surface by clean rags and the surface shall be brushed,
swept, de-dusted and blown off with compressed air / steam to remove all loose
matter. Finally the surface may be washed with water and dried for effective
cleaning.
5.3
Non compatible shop coat primer
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The compatibility of finishing coat should be confirmed from the paint

manufacturer. In the event of use of primer such as zinc Rich epoxy, inorganic
zinc silicate etc. as shop coat, the paint system shall depend on condition of shop
coat. If shop coat is in satisfactory condition showing no major defects, the shop
coat shall not be removed. The touch up primer and finishing coat(s) shall be
identified for application by Engineer-in charge.
5.4
Shop coated (coated with primer & finishing coat) equipment should not be
repainted unless paint is damaged.
5.5
Shop primed equipment and surfaces will only be 'spot cleaned' in damaged
areas by means of power tool brush cleaning and then spot primed before
applying one coat of field primer unless otherwise specified. If shop primer is not
compatible with field primer then shop coated primer should be completely
removed before application of selected paint system for particular environment.
For packaged units / equipment, shop primer should be as per the paint system
given in this specification. However, manufacturer's standard can be followed
after review.
5.6
5.7
Coating Procedure and Application :
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious
air bone elements exists, when the steel surface temperature is less than 50F
above dew point, when the relative humidity is greater than 85% or when the
temperature is below 40F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as
soon as practicable but in no case later than 4 hrs. in the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a
continuous film uniform thickness free of probes. Any spots or areas missed in
application shall be recoated and permitted to dry before the next coat is applied.
Applied paint should have the desired wet film thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an
additional coat can be applied without the development of any detrimental film
irregularities, such as lifting or loss of adhesion of the under coat. Manufacturer
instruction shall be followed for inter coat interval.
5.7.5 When the successive coat of the same colour have been specified, alternate coat
shall be tinted, when practical, sufficiently to produce enough contrast to indicate
complete coverage of the surface. The tinting material shall be compatible with
the material and not detrimental to its service life.
5.7.6 Air spray application shall be in accordance with the following:
a.
The equipment used shall be suitable for the intended purpose, shall be
capable of properly atomizing the paint to be applied, and shall be equipped
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with suitable pressure regulators and gauges. The air caps, nozzles, and
needles shall be those recommended by the manufacturer of the equipment
for the material being sprayed. The equipment shall be kept in satisfactory
condition to permit proper paint application.
b.
Traps or separators shall be provided to remove oil and condensed water

from the air. These traps or separators must be of adequate size and
must be drained periodically during operations. The air from the spray gun
impinging against the surface shall show no condensed water or oil.
c.
Ingredients shall be kept properly mixed in the spray pots or containers

during application by continuous mechanical agitation.
d.
The pressure on the material in the pot and the air at the gun shall be
adjusted for optimum spraying effectiveness. The pressure on the material
in the pot shall be adjusted when necessary for changes in elevation of the
gun above the pot. The atomizing air pressure at the gun shall be high
enough to properly atomize the paint but not so high as to cause excessive
fogging of paint, excessive evaporation of solvent, or less by overspray.
e.
Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and
other foreign materials are not deposited in the paint film.
Any solvents left in the equipment shall be completely removed before
applying paint to the surface being painted.
f.
Paint shall be applied in a uniform layer, with overlapping at the edge of the
spray pattern. The spray patterns shall be adjusted so that the paint is
deposited uniformly. During application, the gun shall be held perpendicular
to the surface and a distance which will ensure that a wet layer of paint is
deposited on the surface. The trigger of the gun should be released at the
end of each stroke.
g.
All runs and sags shall be brushed out immediately or the paint shall be
removed and the surface repainted.
h.
Areas inaccessible to the spray gun shall be painted by brush; if not

accessible by brush, daubers or sheepkins shall be used.
i.
All name plates, manufacturer's identification tags, machined surfaces,

instrument glass, finished flange faces, control valve items and similar items
shall be masked to prohibit coating deposition. If these surfaces are coated,
the component shall be cleaned and restored to its original condition.
j.
Edges of structural shapes and irregular coated surfaces shall be coated first
and an extra pass made later.
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k.
If spray gun shows choking, immediately de-choking procedure shall be

followed.
5.7.7 Airless spray application shall be in accordance with the following procedure: as
per steel structure paint Manual Vol. 1 & Vol.2 by SSPC, USA. Air less spray
relies on hydraulic pressure rather than air atomization to produce the desired
spray. An air compressor or electric motor is used to operate a pump to produce
pressures of 1,000 to 6,000 psi. Paint is delivered to the spray gun at this pressure
through a single hose within the gun; a single paint stream is divided into separate
streams, which are forced through a small orifice resulting in atomization of paint
without the use of air. This results in more rapid coverage with less overspray.
Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose
that sucks paint from any container, including drums. The unit shall have inbuilt
agitator that keep the paint uniformly mixed during the spraying. The unit shall
consist of inbuilt strainer. A usually very small quantity of thinning is required
before spray. Incase of High Build epoxy coatings (two pack), 30: 1 pump ratio
and 0.020-0.023" tip size will provide a good spray pattern. Ideally fluid hoses
should not be less than 3/8" ID and not longer than 50ft to obtain optimum
results.
In case of gun choking, dechoking steps shall be followed immediately.
5.7.8 Brush application of paint shall be in accordance with the following :
a.
Brushes shall be of a style and quality that will enable proper application of
paint.
b.
Round or oval brushes are most suitable for rivets, bolts, irregular surfaces,
and rough or pitted steel. Wide flat brushes are suitable for large flat areas,
but they shall not have width over five inches.
c.
Paint shall be applied into all corners.
d.
Any runs or sags shall be brushed out.
e.
There shall be a minimum of brush marks left in the applied paint.
f.
Surfaces not accessible to brushes shall be painted by spray, daubers, or

sheepkin.
5.7.9 Manual Application by sling (where 6O clock position of pipe is not approachable)
A canvas strip (alternatively a tinplate strip) about 450mrn wide and 1.5m long is
hold under the pipe by two men. Liquid coating is poured on the sling at each
side of the pipe. The men holding this sling move it up and down and walk
slowly forward while fresh coating is poured on the pipe and they manipulate the
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sling so that an even coating is obtained all round the bottom. This work shall be
done very carefully and by experienced personnel. There shall not be any
formation of "Whiskers" and holes in the coating. The coating film shall be
inspected by mirror.
5.7.10 For each coat, the painter should know the WFT corresponding to the specified
DFT and standardize the paint application technique to achieve the desired WFT.
This has to be ensured in the qualification trial.
5.8
Drying of coated Surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without the
development of any film irregularities such as lifting or loss of adhesion of
undercoats. Drying time of the applied coat should not exceed maximum specified
for it as a first coat; if it exceeds the paint material has possibly deteriorated or
mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause checking,
wrinkling, blistering formation of pores, or detrimentally affect the condition of
the paint.
5.8.3 No drier shall be added to a paint on the job unless specifically called for in the
manufacturer's specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and
freezing until dry to the fullest extent practicable.
5.9
Repair of damaged paint surface
5.9.1 Where paint has been damaged in handling and in transportation, the repair of
damaged coating of pre-erection / fabrication shall be as given below.
5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding:
Quickly remove the primer from damaged area by mechanical scraping and
emery paper to expose the white metal. Blast clean the surface if possible.
Feather the primer over the intact adjacent surface surrounding the damaged
area by emery paper.
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of 90C to 500C.
Surface preparation shall be done as per procedure 5.9.2.

One coat of F-9 shall be applied wherever damaged was observed on preerection / pre-fabrication / shop primer of inorganic zinc silicate coating (F9). F-9 shall not be applied if damaged area is not more than 5x5 cm.
5.10 PAINT APPLICATION
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5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted
surface.
5.10.2 Shop priming / pre-erection priming with F9 or F12 shall be done only with
airless spray.
5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush
can be used.
5.11 Documentation
A written quality plan with procedure for qualification trials and for the actual work.
Daily progress report with details of weather conditions, particular of applications,

no of coats and type of materials applied, anomalies, progress of work versus
programmed.
Results of measurement of temperatures relative humidity, surface profile, film

thickness, holiday detection, adhesion tests with signature of appropriate authority.
Particulars of surface preparation and paint application during trials and during the
work.
Details of non-compliance, rejects and repairs.
Type of testing equipments and calibration.
Code and batch numbers of paint materials used.
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6.0
PAINT MATERIALS
Paint manufacturer shall furnish all the characteristics of the paint material on
printed literature, along with the test certificate for all the specified characteristics
given in this specification. All the paint materials shall be of first quality and
confirm to the following general characteristics as per tables 6.1, 6.2 & 6.3.
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F-14: Specially formulated polyamine cured coal tar epoxy suitable for -450C to 125C for
application under insulation
F-15: Two pack cold cured epoxy phenolic coating suitable for -450C to 125C for
application under insulation
F-16: Epoxy siloxane Amercoat 738
Notes:
1.0
Covering capacity and DFT depends on method of application. Covering capacity

specified above are theoretical. Allowing the losses during the application,
minimum specified DFT should be maintained.
2.0
All primers and finish coats should be cold cured and air dried unless otherwise
specified.
3.0
All paints shall be applied in accordance with manufacturer's instructions for

surface preparation, intervals, curing and application. The surface preparation,
quality and workmanship should be ensured.
4.0
Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
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6.4
List of recommended manufacturers

The paints shall conform to the specifications given above and the best quality in
their products range of the manufacturers listed in Annexure-I.
7.0
PAINT SYSTEMS
The paint system should vary with type of environment envisaged in and around
the plants. Three types of environment as given below are considered for selection
of paint system. The paint system is also given for specific requirements.
PRIMERS & FINISH COATS COVERED IN TABLE NOS.7.0 to 15.0
PRIMERS
P-2
Chlorinated Rubber Zinc Phosphate Primer
P-4
Etch Primer / Wash Primer
P-6
Epoxy Zinc Phosphate Primer
FINISH COATS / PAINTS

F-2
Acrylic - Polyurethane finish paint
F-3
Chlorinated Rubber Finish Paint
F-6
High Build Epoxy finish coating
F-7
High Build Coal Tar epoxy coating
F-8
Self priming surface Tolerant High Build Epoxy coating
F-9
Inorganic Zinc Silicate coating
F-11
Heat resistant Synthetic medium based Aluminum paint
F-12
Heat resistant Silicone Aluminum paint
F-14
Specially formulated polyamine cured coal for Epoxy coating
F-15
Epoxy phenolic coating
F-16
Epoxy Siloxane coating: Amercoat 738
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17.0 STORAGE:
17.1
All paints and painting materials shall be stored only in rooms to be arranged by
contractor and approved by Engineer-in-charge for the purpose. All necessary
precautions shall be taken to prevent fire. The storage building shall preferably
be separate from adjacent building. A signboard bearing the words "PAINT
STORAGE- NO NAKED LIGHT- HIGHLY INFLAMABLE" shall be clearly displayed
outside.
18.0 COLOUR CODE FOR PIPING:

For identification of pipelines, the colour code as per Table 18.1 shall be used.
Paint materials for color coding shall be as specified in this standard in clause6.0.
18.1 Colour coding scheme for pipes, equipment, machinery & structures:
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18.2
The colour code scheme is intended for identification of the individual group of
the pipeline. The system of colour coding consists of a ground colour and colour
bands superimposed on it.
18.3
Ground Colours as given in Table-18.1 shall be applied throughout the entire

length for un insulated pipes, on the metal cladding & on surfaces covered by
Clause 2.2.2, ground colour coating of minimum 2m length or of adequate length
not to be mistaken as colour band shall be applied at places requiring colour
bands. Colour band(s) shall be applied at the following location.
a.
At battery limit points
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b.
Intersection points & change of direction points in piping ways.
c.
Other points, such as midway of each piping way, near valves, junction
joints of service appliances, walls, on either side of pipe culverts.
d.
For long stretch / yard piping at 50M interval.
e.
At start and terminating points.
18.4 Identification Sign

18.4.1 Flow direction shall be indicated by an arrow in the location stated in Para
b ,c & d and as directed by Engineer-in-Charge.
a,
18.4.2 Colours of arrows shall be black or white and in contrast to the colour on which
they are superimposed.
18.4.3 Product names shall be marked at pump inlet, outlet and battery limit in a
suitable size as approved by Engineer-in-Charge.
18.4.4 Size of arrow shall be either of those given in 18.5.
18.5 Colour Bands
18.5.1 As a rule, minimum width of colour band shall conform to the following table.
Note: For insulated pipes, nominal pipe size means the outside diameter of the
insulation.
Nominal pipe size figures are to be in inches.
18.5.2 Colour band(s) shall be arranged in the sequence shown in Table 18.1 and the
sequence follows the direction of flow. The relative proportional width of the first
colour band to the subsequent bands shall be 4: 1, minimum width of any band
shall be as per Clause 18.5.1.
18.6
Whenever it is required by the Engineer-in-Charge to indicate that a pipeline

carries a hazardous material, a hazard marking of diagonal strips of black and
golden yellow as per IS:2379 shall be painted on the ground colour.
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19.0 IDENTIFICATION OF VESSELS, PIPING ETC.:

19.1
Equipment number shall be stenciled in black or white on each vessel, column,

equipment & machinery (insulated or un insulated) after painting. Line number in
black or white shall be stenciled on all the pipe lines of more than one location
as directed by Engineer-in-Charge, Size of letters printed shall be as below:
Column & Vessels
Pump, compressor and other machinery
Piping
150 mm (high)
50 mm (high)
40 - 150 mm
19.2 Identification of storage tanks:

The storage tanks shall be marked as detailed in the drawing.
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS:
21.1
Following items shall be painted for camouflaging if required by the client.

a.
b.
c.
d.
20.2
All columns
All tanks in offsites.
Large Vessels
Spheres
Two coats of selected finishing paint as per defense requirement shall be applied
in a particular pattern as per 20.3 and as per the instructions of Engineer-inCharge.
20.3 Method of camouflaging

20.3.1 Disruptive painting for camouflaging shall be done in three Colours in the ratio of
5:3:2 (Dark Green : Light Green : Medium Brown) (all matt finish).
20.3.2 The patches should be asymmetrical and irregular.
20.3.3 The patches should be inclined at 30 Degree to 60 Degree to the horizontal.
20.3.4 The patches should be continuous where two surfaces meet at an angle.
20.3.5 The patches should not coincide with corners.
20.3.6 Slits and holes shall be painted in dark shades.
20.3.7 Width of patches should be 1 to 2 meters.
21.0 INSPECTION AND TESTING
21.1
All painting materials including primers and thinners brought to site by contractor
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for application shall be procured directly from manufactures as per specifications

and shall be accompanied by manufacturer's test certificates. Paint formulations
without certificates are not acceptable.
21.2
Engineer-in-Charge at his discretion may call for tests for paint formulations.
Contractor shall arrange to have such tests performed including batch wise test of
wet paints for physical & chemical analysis. All costs there shall be borne by
the contractor.
21.3
The painting work shall be subject to inspection by Engineer-in-Charge at all

times. In particular, following stage wise inspection will be performed and
contractor shall offer the work for inspection and approval of every stage before
proceeding with the next stage. The record of inspection shall be maintained in
the registers. Stages of inspection are as follows:
a.
Surface preparation
b.
Primer application
c.
Each coat of paint
In addition to above, record should include type of shop primer already applied
on equipment e. g. Red oxide zinc chromate or zinc chromate or Red lead primer
etc.
Any defect noticed during the various stages of inspection shall be rectified by
the contractor to the entire satisfaction of Engineer-in-Charge before proceeding
further. Irrespective of the inspection, repair and approval at intermediate stages
of work, contractor shall be responsible for making good any defects found
during final inspection / guarantee period / defect liability period as defined in
general condition of contract. Dry film thickness (DFT) shall be checked and
recorded after application of each coat and extra coat of paint should be applied to
make-up the DFT specified without any extra cost to owner, the extra cost
should have prior approval of Engineer-In-Charge .
21.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices,
corners, sharp edges etc. in the presence of inspector nominated by Engineer-inCharge.
21.5
The shades of successive coats should be slightly different in colour in order to

ensure application of individual coats, the thickness of each coat and complete
coverage should be checked as per provision of this specification. This should be
approved by Engineer-in-Charge before application of successive coats.
21.6
The contractor shall provide standard thickness measurement instrument with

appropriate range(s) for measuring Dry film thickness of each coat, surface profile
page for checking of surface profile in case of blast cleaning, Holiday detectors and
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pinhole detector and positector whenever required for checking in case of

immersion conditions.
21.7
Prior to application of paints on surfaces of chimneys, the thickness of the

individual coat shall be checked by application of each coat of same paint on
M.S. test panel. The thickness of paint on test panel shall be determined by
using gauge such as 'Elkometer'. The thickness of each coat shall be checked as
per provision of this specification. This shall be approved by Engineer-in-Charge
before application of paints on surface of chimney.
21.8
At the discretion of Engineer-in-Charge, the paint manufacturer must provide the

expert technical service at site as and when required. This service should be free
of cost and without any obligation to the owner, as it would be in the interest of
the manufacturer to ensure that both surface preparation and application are
carried out as per their recommendations.
21.9
Final inspection shall include measurement of paint dry film thickness, Adhesion,
Holiday detection check of finish and workmanship. The thickness should be
measured at as many points/locations as decided by Engineer-in-Charge and
shall be within + 10% of the dry film thickness, specified in the specifications.
21.10 The contractor shall arrange for spot checking of paint materials for Sp. gr., flow
time(ford cup) and spreading rate.
22.0 GUARANTEE
22.1
The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein / to be
provided during execution of work.
22.2
The contractor shall produce test reports from manufacturer regarding the
quality of the particular batch of paint supplied. The Engineer-in-Charge shall
have the right to test wet samples of paint at random, for quality of same, as
stipulated in Clause 11 above. Batch test reports of the manufacturer's for each
batch of paints supplied shall be made available by the contractor.
23.0 QUALIFCATION CRITERIA OF PAINTING CONTRACTOR:

Painting contractor who is awarded any job for GAIL, Projects under this standard
must have necessary equipments, machinery, tools and tackles for surface preparation,
paint application and inspection. The contractor must have qualified,
trained
and
experienced surface preparator , paint applicator, inspector and
supervisors.
The
contractor supervisor, inspector, surface preparator and
paint applicator must be
conversant with the standards referred in this specification. The contractors capacity,
capability and competency requirements
for the job shall be quantified in the
tender document and shall be assessed by
GAIL team before awarding any job.
24.0 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND
MANUFACTURERS
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NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 40 of 49
Following procedure is recommended to be followed for approval of new

manufacturers.
24.1
The manufacturer should arrange testing of the inorganic zinc silicate coating
materials as per the list of tests given in para 24.5 below from one of the reputed
Government laboratories.
24.2
Samples of coating materials should be submitted to the Govt. laboratory in

sealed containers with batch no. and test certificate on regular format of
manufacturer's testing laboratory. The sampling shall be certified and sealed by a
certifying agency.
24.3
All test panels should be prepared by Govt. testing agency coloured photographs
of test panels should be taken before and after the test and should be enclosed
along with test report.
Sample batch no. and manufacturer's test certificate should be enclosed along
with the report. Test report must contain details of observation and rusting if
any, as per the testing code. Suggested Government laboratories are:
RRL ,Hyderabad
HBTI, Kanpur
DMSRDE, Kanpur
IIT, Mumbai
BIS Laboratories.
UDCT, Mumbai
RITES, Calcutta
PDIL
24.4
Manufacturers should intimate the Company, details of sample submitted for

testing, name of Govt . testing agency, date, contact personnel of the Govt.
testing agency. At the end of the test the manufacturer should submit the test
reports to the company for approval. The manufacturer(s) shall be qualified
based on the results of these tests and other assessment and the Company's
decision in this regard shall be final and binding on the manufacturer.
24.5
Test required for evaluation of acceptance of coating materials for offshore

application.
TEST
GAIL (INDIA) LTD

NEW DELHI
ASTM TEST METHOD

DOCUMENT NO.
S-05-02-014
REV-0
Page 41 of 49
DENSITY
DIPPING PROPERIES
D 1475
D 823
DRYING TIME
FLEXIBILITY
HARDNESS
D 1640
D 1737 / D 522
D 3363
ADHESION
ABRASION RESISTANCE
DFT / COAT
STORAGE STABILITY
D 2197
D 968 / D 1044
AS PER SSPC GUIDELINES
D 1849
FILM CHARACTERSTICS
RESISTANCE TO
HUMIDITY FOR 2000 HRS. SALT SPRAY FOR 2000 HRS
ACCELERATED WEATHERING
%Zn IN DFT
24.6
D 2247
B 117
D 822
G 53
Coating system for panel test shall be decided after discussion with GAIL.
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 42 of 49
ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
INDIAN VENDORS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Asian paints(1) Ltd.

Berger Paints Ltd.
Goodlass Nerolac paints Ltd.
Jenson and Nicholson paints Ltd. & ChokuGu Jenson & Nicholson Ltd.
Shalimar paints Ltd.
Sigma coatings, Mumbai
CDC Carboline Ltd.
Premier products Ltd.
Coromandel paints & chemicals Ltd.
Anupam enterprises
Grand polycoats
Bombay paints Ltd.
Vanaprabha Esters & Glycer , Mumbai
Sunil paints and Varnishes Pvt. Ltd.
Courtaulds coatings & Sealants India(Pvt.) Ltd.
Mark-Chem Incorporated, Mumbai (for phosphating chemicals only)
VCM Polyurethane Paints (for polyurethane paints only)
FOREIGN VENDORS FOR OVERSEAS PRODUCTS

1.
2.
3.
4.
5.
6.
Sigma coatings, Singapore

Ameron, USA.
Kansai paint, Japan
Hempel paints, USA.
Valspar Corporation, USA
Courtaulds coatings, UK.
Note : This list is subjected to revision based on fresh approval.
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 43 of 49
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 44 of 49
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 45 of 49
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 46 of 49
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 47 of 49
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 48 of 49
GAIL (INDIA) LTD

NEW DELHI

DOCUMENT NO.
S-05-02-014
REV-0
Page 49 of 49
INSPECTION AND TEST PLAN FOR GASKETS
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
S 05 06 - 001
REV- 0
Page 1 of 4
SL.
NO.
STAGE
COMPONENT
CHARACTER
ISTICS
METHOD OF
CHECK
QUANTUM
OF CHECK
REFERENCE
DOC.
ACCEPTANCE
NORMS
RECORD
SCOPE OF INSPECTION
SUB
VENDOR
VENDO
R
GAIL
1.0
CAF
GASKETS
1.1
Raw Material
Inspection
CAF Material
Physical
Visual,
Dimensional, TC
Verification
100 %
IS 2712 Gr.
W/1
IS 2712 Gr.
W/1
Manufacturers
TC
1.2
In process
inspection
(punching &
finishing)
CAF Material
Identification
Verification
Visual,
Dimensional
As per
internal QA
Plan
ANSI B
16.21, PO,
Material
Specification
ANSI B 16.21,
PO, Material
Specification
Inspection
Report
1.3
Final
Inspection
Gasket
Identification
Verification
Visual,
Dimensional
100% by
Vendor, at
random by
GAIL
ANSI B
16.21, PO,
Material
Specification
ANSI B 16.21,
PO, Material
Specification
Inspection
Report
2.0
SPIRAL
WOUND
2.1
Raw Material
Inspection
(Review of
mfrs
certificate and
check test)
Metaalic spiral
winding
material,
centering ring,
Inner ring
Chemical,
Visual,
Dimensional
Lab Check Visual
100 % lots
Applicable
Material
specification
Applicable
Material
specification
Manufacturers
TC
W&R
2.2
Raw Material
Inspection
(Review of
mfrs
certificate and
check test)
Non- Metallic
filler material
Physical
Visual Dimension
TC Verification
100 %
Applicable
Material
specification
Applicable
Material
specification
Manufacturers
TC
W&R
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
S 05 06 - 001
REV- 0
Page 2 of 4
SL.
NO.
STAGE
COMPONENT
CHARACTER
ISTICS
METHOD OF
CHECK
QUANTUM
OF CHECK
REFERENCE
DOC.
ACCEPTANCE
NORMS
RECORD
SCOPE OF INSPECTION
SUB
VENDOR
VENDO
R
GAIL
2.3
Raw material
inspection
Spiral Wound
Compression
& recovery
test
Test Jig
Lots of every
size / rating
ANSI B
16.20, PO,
Material
Specification
ANSI B 16.20,
PO, Material
Specification
Inspection report
2.4
Final
Inspection
Gasket
Identification
Verification
Visual Dimension,
Marking
100 % by
vendor, at
random by
GAIL
ANSI B
16.21, PO,
Material
Specification
ANSI B 16.21,
PO, Material
Specification
Inspection report
3.0
RTJ GASKET
3.1
Raw material
inspection
(Document
Review)
Seamless ring
gasket material
Properties
Chemical
Dimension, visual,
Hardness
100 %
ANSI B
16.20, PO,
Material
Specification
ANSI B 16.20,
PO, Material
Specification
TC, Inspection
report
3.2
Raw material
inspection
(Check Test)
Ring Gasket
Material
Properties
Dimension, visual,
Hardness
At random
ANSI B
16.20, PO,
Material
Specification
ANSI B 16.20,
PO, Material
Specification
Inspection report
3.3
Final
Inspection
Gasket
Identification,
Verification
Dimension, visual,
Hardness
At random
ANSI B
16.20, PO,
Material
Specification
ANSI B 16.20,
PO, Material
Specification
TC, Inspection
report
3.4
Final
Inspection
(Non CS)
Gasket
PMI Check
X-Ray
Floorescence/
Emission
Spectrometer
Std. Spec for

PMI
Std. Spec for

PMI
Material
Specification
Inspection
Report
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
S 05 06 - 001
REV- 0
Page 3 of 4
4.0
JACKETED
GASKET
4.1
Raw material
Inspection
Metal Jacketed
Properties
Chemical,
Dimension
thickness, Visual
As per
sampling
plan
IS 513
IS 513
TC, Inspection
report
4.2
Raw material
Inspection
Filler
Properties
Dimension, visual,
Hardness
At random
ANSI B
16.20, PO,
Material
Specification
ANSI B 16.20,
PO, Material
Specification
Inspection report
4.3
Final
Inspection
Gasket
Identification
verification
Dimension, visual,
Hardness
At Random
ANSI B
16.20, PO,
Material
Specification
ANSI B 16.20,
PO, Material
Specification
TC, Inspection
report
4.4
Final
Inspection
(Non CS)
Gasket
PMI Check
X-Ray
Floorescence/
Emission
Spectrometer
Std. Spec for

PMI
Std. Spec for

PMI
Material
Specification
Inspection
Report
Legend : H Hold (Offer for witness & obtain clearance), W Witness, R Review, A Approval, I Information, X Submit, PO Purchase Order, PR Purchase Requisition.
In case of conflict between purchase specification , contract documents and ITP more stringent conditions shall be applicable.
GAIL (INDIA) LTD

NEW DELHI
SPECIFICATION
S 05 06 - 001
REV- 0
Page 4 of 4
FOR
POSITIVE MATERIAL IDENTIFICATION
(PMI)
AT VENDORS WORKS
GAIL (INDIA) LTD

NEW DELHI

(PMI) AT VENDORS WORKS
SPECIFICATION
S 14 02 001
REV-0
Page 1 of 7
CONTENTS
1.0
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
DEFINITIONS
4.0
PMI EXAMINATION
5.0
ACCEPTABLE METHODS FOR PMI
6.0
EXTENT OF PMI EXAMINATION
7.0
RECORDING AND DOCUMENTATION
8.0
MARKING
GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION
S 14 02 001
REV-0
Page 2 of 7
1.0
SCOPE
This specification applies to the requirements for Positive Material Identification (PMI)
to be performed at the vendors works on Metallic Alloys Materials procured either
directly by the GAIL/Owner/Contractor or indirectly through the sub-vendors.
1.2
Any post order deviation from this specification must be approved by Owner/ GAIL in
the Deviation/ Waiver Permit Format enclosed with Material Requisition.
1.3
This specification covers the procedures and methodology to be adopted to assure that
the chemical composition of the alloy material is consistent with the material
specifications as specified in purchase documents using Alloy Analyzer at the time of
final inspection before dispatch.
1.4
The scope of this specification shall include but shall not be limited to Positive Material
Identification (PMI) to be performed on Alloy Materials listed below:
-
Alloy Steel Pipes including Pipes
Alloy Steel Flanges & Forgings
Alloy Steel Fittings including Clad Fittings
Alloy Steel fasteners
Alloy Cast & Forged steel valves
Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)
Longitudinal Pipe & Fittings Welds.
Gaskets (for Ring Type Joints)
Following Items shall be excluded from scope of PMI examination:

-
Gasket other than for Ring Type Joints
Internal Components of Valves
1.5
All grades of material supplies including Stainless Steels shall be liable for PMI test at
site. In case of any defective materials being found at site, the vendor shall be
responsible to effect replacement of such defective materials at project site without any
delays to the satisfaction of GAIL.
2.0
REFERENCE DOCUMENTS
GAIL (INDIA) LTD
NEW DELHI

SPECIFICATION
S 14 02 001
REV-0
Page 3 of 7
2.1
API Recommended Practice 578 (First Edition, May 1999) Material Verification
Programme for new and Existing Alloy Piping System.
3.0
DEFINITIONS
3.1
Vendor: Any Supplier or Manufacturer on whom an order is placed for the supply of
referred items. This definition shall also include any sub-vendor or manufacturer on
whom a sub- order is placed by the vendor.
3.2
Inspection Lot: A group of items offered for inspection covered under same size, Heat
and Heat treatment lot.
3.3
Alloy Material: Any metallic material (including welding filler material) that contains
alloying elements such as chromium, nickel, molybdenum or vanadium, which are
intentionally added to enhance mechanical or physical properties and/ or corrosion
resistance.
4.0
PMI EXAMINATION
4.1
The vendor shall submit a procedure of PMI to comply with the requirements of this
Specification Approval of PMI Procedure shall be obtained from Owner/ GAIL/ TPI prior
to commencing manufacture/ inspection of product.
4.2
PMI examination of alloy materials is independent of any certification, markings or

colour coding that may exist and is aimed at verifying that the alloy used are as per
specified grades.
4.3
The Vendor shall identify all incoming alloy materials and maintain full traceability of all
alloy materials, including all off-cuts. Transfer of identification marks shall be
undertaken prior to cutting to ensure maintenance of identification on off-cuts.
4.4
The Vendor shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or
alloy material with carbon steel. Non ferro-magnetic materials shall be segregated at all
times from ferro-magnetic materials.
4.5
PMI examination is subject to surveillance inspection by Owner/ GAIL/ TPI.
5.0
ACCEPTABLE METHODS FOR PMI
5.1
The method used for PMI examination shall provide a quantitative determination of the
alloying elements like Cr, Mo, Ni, V in Alloy Steel items.
GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION
S 14 02 001
REV-0
Page 4 of 7
5.2
Instrument or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of alloying elements
present.
5.3
The acceptable instruments for alloy analyzer shall be either Portable X-Ray
Fluorescence or Optical Emission type each capable of verifying the percentage of
alloy elements within specified range.
5.4
Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.
5.5
The PMI instruments shall have the sensitivity to detect the alloying elements in the
specified range.
5.6
All PMI instruments shall have been serviced within a 6 month period of the time of use
to verify the suitability of batteries, sources etc, the data of the last service shall be
stated on the PMI Report Form (Sample enclosed).
5.7
Each analyzer must be calibrated according to the manufacturers specification at the

beginning and end of each shift. Instrument must be checked against known standard
for each alloy type to be inspected during the shift.
5.8
Certified samples, with full traceability, of a known alloy materials shall be available for
use as a random spot check on the instrument calibration.
5.9
The surfaces to be examined shall be prepared by light grinding or abrasive paper and
solvent cleaner. Evidence of Arc burn resulting from examination shall be removed by
light grinding or abrasive paper.
5.10 Alloy Steel ring type joint gaskets shall be inspected by using portable X-Ray
Flourescence instrument.
5.11 Testing shall be done as per the procedures outlined by the manufacturers of alloy
analyzer being used. Modification of these procedures if any, must be approved by
Owner/ GAIL.
5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/ GAIL visiting engineer. If the vendor has qualified operator on their rolls, he
may perform the examination. Otherwise PMI examination shall be sub-contracted to an
independent testing agency approved by GAIL.
5.13 Whenever material is identified as not meeting requirements by the visiting engineer a
rejection note shall be issued.
GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION
S 14 02 001
REV-0
Page 5 of 7
6.0
EXTENT OF PMI EXAMINATION
6.1
Following sampling plan shall be applicable for PMI examination of various alloy items:
A. Flanges, Fittings, Valves, RTJ Gaskets
B. Pipes
100%
100% (for pipes procured from
traders)
- 2 random samples drawn from each

size/ Heat/ Lot (for pipes procured
directly from Mills)
C. Fasteners
Lot Size
Sample Size
Upto 100
2% (Min2)
101 to 500
1% (Min 3)
501 and above
0.5% (Min5)
Note:
a.
For Welded Pipes and Fittings, PMI shall be performed on base metal as well as
weldments.
Whenever any sample drawn to PMI test on the basis of percentage selection in
B & C above, fails to meet specification requirements, 100% of items of lot shall
be tested for PMI
7.0
RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in aReport Format as enclosed with
this specification.
8.0
MARKING
8.1
All alloy materials tested by PMI shall be identified using either of the following methods
by indicating PMI OK
8.2
a) Bar Code/ Hologram Sticker

b) A low stress stamp marking
GAIL (INDIA) LTD
NEW DELHI

SPECIFICATION
S 14 02 001
REV-0
Page 6 of 7
POSITIVE MATERIAL IDENTIFICATION REPORT
Page
of
BULK MATERIAL
Project:
Client
Job No
PMI Report No.
Vendor/ sub- Vendor
Purchase Order No:
Testing Agency
Purchase Requisition No:
PMI Location
Bulk Item Type (as per requisition)

Material Specification/ Grade
Number of Items in Lot
Requisition Item No./ Description
Alloy content, Weight (%)
Remarks
Accept/ Reject
Element
Cr
Mo
Ni
Specified range
Actual Observations
1.
2.
3.
4
5
6
7
8
Instrument Type/ ID
Last Service date
GAIL (INDIA) LTD

NEW DELHI
Inspection Agency

Witnessed by
SPECIFICATION
S 14 02 001
REV-0
Page 7 of 7
NOTES:
1.
ALL DIMENSIONS ARE IN MM UNLESS SPECIFICED OTHERWISE.
2.
DIFFERENT ROU DIMENSIONS MAY BE ADOPTED BASED ON SITE CONDITIONS,

CONSTRUCTION METHOD, PIPELINE SIZE, NO. OF PIPELINES AND PROVISION FOR
FUTURE PIPELINES.
3.
THE LOCATION OF PIPELINE IN ROU MAY BE CHANGED TO SUIT SITE CONDITIONS,

AFTER OBTAINING WRITTEN APPROVAL FROM COMPANY.
4.
FOR LOCATION OF PIPELINE AMRKET WITH RESPECT TO PIPELINE CENTERLINE, REFER

APPLICABLE STANDARDS FOR MARKERS.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL RIGHT OF USE FOR PIPE

LINES
DOCUMENT NO.
S-04-01-001
REV-0
Page 1 of 2
5.
ROU WIDTH (A) AND LOCATION OF PIPELINE IN ROU (B) SHOWN IN THIS STANDARD
SHALL BE APPLICABLE FOR NEW CONSTRUCTION OF SINGLE PIPELINE IN NORMAL
TERRAIN.FOR RESTRICTIONS, IF ANY IN ROU, REFER PROJECT SPECIFIC REQUIREMENTS
OF CONTRACT.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL RIGHT OF USE FOR PIPE

LINES
DOCUMENT NO.
S-04-01-001
REV-0
Page 2 of 2
NOTES:
1.
ALL DIMENSIONS ARE IN MM UNLESS SPECIFICED OTHERWISE.
2.
TRENCH DIMENSIONS / COVER REQUIREMENTS SHOWN IN THIS STANDARD ARE

MINIMUM REQUIRED DIMENSIONS. ANY INCREASE IN TRENCH WIDTH / COVER SHALL
BE SPECIFIED IN THE PROJECT SPECIFIC REQUIREMENTS OF CONTRACT.
3.
MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED

AUTHORITIES HAVING JURISDICTION OVER THE AREA.
4.
EXTRA COVER REQUIREMENTS SHALL BE PROVIDED AT OVER BENDS AND SAG BENDS
AS REQUIRED DURING CONSTRUCTION.
5.
FOR MINIMUM COVER REQUIREMENTS AT PIPELINE CROSSING ROADS, RAILWAY

TRACKS, RIVERS, MARSHY AREAS, WATER (CANAL) BODIES ETC., REFER RELEVENT
STANDARD.
6.
FOR ALL PIPELINES TO BE CONSTRUCTED UNDER THE JURISDICTION OF GOVT. OF

INDIA, THE MINIMUM COVER TO BE ADOPTED SHALL BE 1000 MM, IN ACCORDANCE
WITH PETROLEUM AND MINERAL PIPELINES (ACQUSITION OF RIGHT OF USER IN LAND)
ACT NO. 50, 1962 AND AMENDMENTS THREON, OF GOVT. OF INDIA.
7.
REFER APPLICABLE STANDARDS AND DRAWINGS FOR OFC.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL TRENCH DIMENSIONS FOR

PIPE LINES
DOCUMENT NO.
S-04-01-002
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
PIPE LINE SYMBOLS
S-04-01-003
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TOPOGRAPHICAL SYMBOLS
S-04-01-004
REV-0
Page 1 of 1
NOTES:
1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.
2. A MODIFIED PIPELINE WARNING SIGN SHALL BE INSTALLED WHERE THE PIPELINE CROSSES
AN EXISTING PIPELINE CARRYING HAZARDOUS FLUID.
3. CONCRETE SLAB SHALL BE PCC M15 AS PER IS 456 / PLASTIC GRATING SHALL BE 6 MM THK.
4. PLASTIC GRATING OR CONC. SLAB NEED NOT BE PROVIDED BETWEEN AN EXISTING
PIPELINE AND A NEW CASED PIPELINE.
5. APPROVAL OF CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.
6. DIMENSION A SHALL BE CALCULATED USING FORMULS A = (D1+D2+---+Dn)+(n-1) X500
WHERE D1, D2 _ _ _ IS THE DIAMETER OF PIPELINES IN MM IN THE SAME TRENCH AND n IS
NO. OF PIPELINES IN SAME TRENCH.
GAIL (INDIA) LTD

NEW DELHI
EXISTING PIPELINE ON SLEEPER

CROSSING
DOCUMENT NO.
S-04-01-005
REV-0
Page 1 of 2
7. DIMENSION D SHALL BE THE LARGEST DIAMETER OF THE PIPELINE LAID IN SAME TRENCH.
8. TRENCH DIMENSIONS SHALL BE IN ACCORDANCE WITH RELEVENT STANDARDS /
SPECIFICATIONS.
GAIL (INDIA) LTD

NEW DELHI
EXISTING PIPELINE ON SLEEPER

CROSSING
DOCUMENT NO.
S-04-01-005
REV-0
Page 2 of 2
NOTES:
2. ROAD / HIGHWAY CROSSING SHALL BE RESTORED TO ORIGINAL CONDITION TO THE ENTIRE
SATISFACTION OF COMPANY AND CONCERNED AUTHORITIES HAVING JURISDICTION.
3. REFER API 1102
REQUIREMENTS.
(LATEST
EDITION)
FOR
OTHER
DESIGN
AND
INSTALLATION
4. ANGLE OF INTERSECTION BETWEEN PIPE LINE AND THE ROAD / HISGHWAY SHALL BE AS
CLOSE TO 900 AS POSSIBLE, BUT IN NO CASE LESS THAN 300.
5. IN CASE PIPE LINE COATING IS LIABLE TO GET DAMAGED WHILE BORING / JACKING, A
PROTECTIVE COATING OF CONCRETE OR ANY OTHER SUITABLE MATERIAL SHALL BE
PROVIDED ON CARRIER PIPE IN ACCORDANCE WITH SPECIFICATIONS AND AS DIRECTED BY
COMPANY.
6. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS
FOR EACH ROAD / HIGHWAY CROSSED AND PREPARE DETAILED DRAWING FOR INDIVIDUAL
CROSSING FOR COMPANYS APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
GAIL (INDIA) LTD

NEW DELHI
PIPE LINE ROAD / HIGHWAY

UNCASED CROSSING
DOCUMENT NO.
S-04-01-006
REV-0
Page 1 of 1
NOTES:
1. ALL DIMENSIONS ARE IN mm, UNLESS SPECIFIED OTHERWISE.
2. VENT AND DRAIN OFF TO FACE LEFT WHEN LOOKING IN DIRECTION OF FLOW AND SHALL BE
PARALLEL TO CROSSING.
3. VENT AND DRAIN OFF PIPE SHALL BE API 5L Gr. B OR IS 1239.
4. PORTION OF VENT AND DRAIN OFF PIPES WHICH ARE UNDER GROUND OR WHICH MAY BE
UNDER WATER ARE TO BE COATED WITH COAL TAR EPOXY (MIN. 300 MICRON THK.) PAINTING
FOR PORTION ABOVE GROUND / WATER LEVEL SHALL BE AS PER STANDARD SPECIFICATION
FOR SHOP AND FIELD PAINTING NO. S-05-02-014.
5. VENT PIPES MAY BE USED FOR MOUNTING WARNING SIGNS.
6. FOR CASING PIPE REFER, STANDARD NO. S-04-01-008, SCOPE OF WORK AND SOR.
GAIL (INDIA) LTD

NEW DELHI
DETAILS OF CASING VENT AND

DRAIN OFF
DOCUMENT NO.
S-04-01-007
REV-0
Page 1 of 1
NOTES:
1. THE CASING PIPE SHALL BE DESIGNED IN ACCORDANCE WITH API 1102 (LATEST EDITION).
2. CASING PIPE, NORMALLY, IS NOT TO BE COATED. HOWEVER, IN HIGHLY CORROSIVE AREAS THE
CASING SHALL BE COATED, WRAPPED AND CATHODIC PROTECTION PROVIDED WITH
SACRIFICIAL ANODE.
3. AT BOTH ENDS OF CASING PIPE, A DOUBLE SET OF INSULATORS SHALL BE INSTALLED.
4. THE MAXIMUM SPACING BETWEEN INSULAORS AS PER MANUFACTURERS RECOMMENDATION,
BUT IN NO CASE MORE THAN 2500 MM.
5. ELECTRICAL INSULATION BETWEEN THE CASING AND CARRIER PIPE SHALL BE CHECKED WITH
SUITABLE MEGGER.
6. CASING INSULATORS AND END SEALS SHALL BE AS PER THE SPECIFICATIONS ISSUED FOR THE
SAME.
7. END SEALS SHOWN HERE ARE ONLY INDICATIVE, POSSIBILITY OF PROVIDING OHER TYPES OF
FLEXIBLE END SEALS MAY BE CONSIDERED.
8. TO PREVENT DAMAGE TO COATING AND WRAPPING (IF APPLIED) TO CASING PIPE IN CASE OF
BORED / JACKED CROSSING, A PROTECTIVE COATING OF CONCRETE OR SUITABLE MATERIAL
SHALL BE PROVIDED ON CASING PIPE.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
CASING PIPE DETAILS
S-04-01-008
REV-0
Page 1 of 1
NOTES:
5. SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN CROSSING
PIPELINES. IN SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. CP
DETAILS ARE COVERED SEPARATELY.
GAIL (INDIA) LTD

NEW DELHI
EXISTING UNDER GROUND PIPE

CROSSING (TYPE I)
DOCUMENT NO.
S-04-01009
REV-0
Page 1 of 2

SPECIFICATIONS.
9. APPROVAL OF THE CROSSING SHALL BE OBTAINED FROM CONCERNED AUTHORITIES.
GAIL (INDIA) LTD

NEW DELHI

CROSSING (TYPE I)
DOCUMENT NO.
S-04-01009
REV-0
Page 2 of 2
NOTES:
5. SUITABLE CATHODIC PROTECTION BONDING SHALL BE PROVIDED BETWEEN CROSSING
PIPELINES. IN SOME CASES THE NEW PIPELINE MAY REQUIRE ELECTRICAL ISOLATION. CP
DETAILS ARE COVERED SEPARATELY.
GAIL (INDIA) LTD

NEW DELHI

CROSSING (TYPE II)
DOCUMENT NO.
S-04-01-010
REV-0
Page 1 of 2

SPECIFICATIONS.
GAIL (INDIA) LTD

NEW DELHI

CROSSING (TYPE II)
DOCUMENT NO.
S-04-01-010
REV-0
Page 2 of 2
NOTES:
5. IN CASE OF ARMOURED AC CABLE, SUITABLE CATHODIC PROTECTION BONDING SHALL BE
PROVIDED BETWEEN PIPELINE AND CABLE ARMOUR. IN CASE OF UNARMOURED AC CABLE,
ARRANGEMENT FOR ELECTROMAGNETIC SHIELDING (BY PROVIDING CASING ON EITHER
PIPE OR CABLE) SHALL BE CONSIDERED. CP DETAILS ARE COVERED SEPARATELY.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
UNDER GROUND CABLE CROSSING
S-04-01-011
REV-0
Page 1 of 2

SPECIFICATIONS.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
UNDER GROUND CABLE CROSSING
S-04-01-011
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
OVERHEAD POWER LINE CROSSING
S-04-01-012
REV-0
Page 1 of 2
NOTE:
2. THIS STANDARD IS APPLICABLE FOR 11 KV AND ABOVE POWER LINES ONLY.
3. SUITABLE MEASURES SHALL BE TAKEN FOR THE PROTECTION OF THE LINE AND SECURITY
OF PERSONNEL WHEREVER FOUND NECESSARY.
4. APPROVAL OF CROSSING MAY HAVE TO BE OBTAINED FROM CONCERNED AUTHORITIES.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
OVERHEAD POWER LINE CROSSING
S-04-01-012
REV-0
Page 2 of 2
NOTE:
2. FOR ALL THE PIPELINES TO BE CONSTRUCTED UNDER THE JURISDICATION OF GOVT. OF
INDIA, THE MINIMUM COVER REQUIREMENT IS 1000 MM IN ACCORDANCE WITH GOVT. OF
INDIA PETROLEUM PIPELINES (ACQUISITION OF ROU IN LAND) ACT, NO. 50 (1962) AND NO.
13 (1977). ANY EXTRA REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATION.
3. THE MINIMUM COVER SHALL BE SUBJECT TO APPROVAL OF CONCERNED AUTHORITIES.
4. THE MINIMUM COVER IS FOR STRAINGHT PIPE RUNS. EXTRA COVER REQUIREMENTS TO BE
ESTABLISHED AT ALL OVER BENDS, SAG BENDS AND HORIZONTAL BENDS.
5. FOR MINIMUM COVER AT PIPELINE CROSSING ROADS, RAILWAY TRACKS, RIVERS, MARSHY
AREAS ETC. REFER RELEVENT STANDARD.
8.
CLEAR SPACING BETWEEN PIPELINES IS ONLY FOR STRAIGHT LENGTHS. SPACING BETWEEN
PIPELINES AT BENDS, RAILWAY CROSSINGS, ROAD CROSSINGS, CANAL CROSSINGS, OTHER
WATER CROSSINGS, MARSHY AREAS SHALL BE AS PER APPROVED DRAWINGS /
SPECIFICATIONS. CLEAR SPACING SHALL BE REVIEWED IN CASE PIPELINES OPERATING AT
TEMPERATURES OTHER THEN AMBIENT.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL TRENCH DIMENSIONS FOR

TWO OR MORE PIPELINES IN
COMMON TRENCH
DOCUMENT NO.
S-04-01-013
REV-0
Page 1 of 1
DETAIL - X
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
KM POST
S-04-01-014
REV-0
Page 1 of 3
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
KM POST
S-04-01-014
REV-0
Page 2 of 3
NOTES:
1.
ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE.
2.
SCHEME OF PAINTING AND COLOURING:
3.
4.
A.
UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE):

COAL TAR EPOXY (MINIMUM 300 MICRONS THK.).
B.
OVERGROUND STEEL STRUCTURE: AS PER STANDARD S-05-02-014.
C.
FIGURES SHALL BE STENCILED ON BOTH SIDES OF THE POSTS IN BLACK.
D.
COLOUR SCHEME FOR PIPELINE CO. MONOGRAM SHALL BE AS DIRECTED BY

COMPANY.
E.
POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK

AND WHITE PAINT.
F.
ALL OTHER ABOVE GROUND STEEL SHALL BE PAINTED YELLOW.
LOCATION:
A.
KM POST SHALL BE INSTALLED AT EVERY KILOMETER AS PER REQUIREMENTS

OF CONTRACT AND AS DIRECTED BY COMPNAY.
B.
COMPANY NAME PLATE SHALL FACE THE PIPE LINE.
C.
KM POST SHALL BE 3000 MM TO THE LEFT OF THE PIPE CENTERLINE VIEWING

TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION SKETCH
ABOVE.
MATERIAL FOR MARKERS SHALL BE:
PLATE
IS 2062 Gr. A
PIPE
IS-1239
5.
THE FOUNDATION SHALL BE MADE OF CONCRETE M20.
6.
THE HEIGHT OF KM POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
KM POST
S-04-01-014
REV-0
Page 3 of 3
LOCATION PLAN FOR BOUNDARY MARKER
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TYPICAL ROU BOUNDARY MARKER
S-04-01-015
REV-0
Page 1 of 2
NOTES:
1.
2.
BOUNDARY MARKERS SHALL BE INSTALLED AT THE ROU LIMITS ON EITHER SIDES AT 250 M
INTERVALS AND ALSO AT ALL TURNING POINTS, AS PER SPECIFICATIONS AND AS
SPECIFIED BY COMPANY. BOUNDARY MARKERS SHALL PREFERABLY BE PLACED ON FIELD
BENDS / UNCULTIVABLE PATCHES.
3.
ALL BOUNDARY MARKERS SHALL BE PRECAST AND INSCRIPTIONS SHALL BE ENGRAVED

CENTRALLY IN THE MOULD ON ONE FACE.
4.
LETTERS SHALL BE 60 MM HIGH AND 5 MM DEEP.
5.
INSCRIPTIONS SHALL FACE THE PIPELINE.
6.
CONCRETE FOR BOUNDARY MARKERS SHALL BE M20.
7.
ABOVE GROUND PART OF BOUNDARY MARKERS SHALL BE PAINTED YELLOW WITH

MINIMUM THREE COATS OF WATER PROOF CEMENT PAINT AS PER IS-5410. INSCRIPTIONS
SHALL BE PAINTED BLACK.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TYPICAL ROU BOUNDARY MARKER
S-04-01-015
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
AERIAL MARKER
S-04-01-016
REV-0
Page 1 of 3
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
AERIAL MARKER
S-04-01-016
REV-0
Page 2 of 3
NOTES:
1.
2.
3.
4.
A.

B.
C.
D.

COMPANY.
E.

AND WHITE PAINT.
F.
LOCATION:
A.
AERIAL MARKER SHALL BE INSTALLED AT EVERY 5 KILOMETERS AS PER

REQUIREMENTS OF CONTRACT AND AS DIRECTED BY COMPNAY.
B.
COMPANY NAME PLATE SHALL BE FIXED ON BOTH SIDES OF THE POST.
C.
AERIAL MARKER SHALL BE 3000 MM TO THE LEFT OF THE PIPE CENTERLINE

VIEWING TOWARDS THE DIRECTION OF FLOW AND AS INDICATED IN LOCATION
SKETCH ABOVE.
PLATE
IS 2062 Gr. A
PIPE
IS-1239
5.
6.
THE HEIGHT OF POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
AERIAL MARKER
S-04-01-016
REV-0
Page 3 of 3
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DIRECTION MARKER
S-04-01-017
REV-0
Page 1 of 3
NOTES:
1.
2.

A.

B.
C.
D.

COMPANY.
E.

AND WHITE PAINT.
F.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DIRECTION MARKER
S-04-01-017
REV-0
Page 2 of 3
3.
4.
LOCATION:
A.
DIRECTION MARKER SHALL BE INSTALLED AT LOCATIONS AS PER

SPECIFICATIONS AS INDICATED IN APPROVED DRAWINGS AND AS DIRECTED BY
COMPNAY.
B.
COMPANY NAME PLATE SHALL FACE THE PIPELINE.
C.
DIRECTION MARKER SHALL BE INSTALLED AT 3000 MM TO THE LEFT OF THE

PIPE CENTERLINE VIEWING TOWARDS THE DIRECTION OF FLOW AND AS
INDICATED IN LOCATION SKETCH ABOVE.
PLATE
IS 2062 Gr. A
PIPE
IS-1239
5.
DIRECTION MARKER SHALL SHOW THE CHANGE IN DIRECTION OF THE PIPELINE.

ALIGNMENT.
6.
7.
THE HEIGHT OF POST MAY BE VARIED TO SUIT FIELD REQUIREMENTS.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DIRECTION MARKER
S-04-01-017
REV-0
Page 3 of 3
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-018
REV-0
Page 1 of 3
NOTES:
2. SCHEME OF PAINTING AND COLOURING:
A.
UNDERGORUND STEEL STRUCTURES (EXCEPT THAT EMBEDDED IN CONCRETE): COAL

TAR EPOXY (MINIMUM 300 MICRONS THK.).
B.
C.
AREAS SHOWN AS ARE TO BE PAINTED AND AREAS SHOWN AS ARE TO BE

PAINTED YELLOW.
D.
ALL LETTERS SHALL BE PAINTED BLACK EXCEPT WARNING WHICH SHALL BE

PAINTED RED.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-018
REV-0
Page 2 of 3
E.

COMPANY.
F.
POST SHALL BE PAINTED WITH 250MM WIDE ALTERNATIVE BANDS OF BLACK AND
WHITE PAINT.
G.
3. LOCATION:
A.
THE PIPE LINE WARNING SIGN SHALL BE INSTALLED IN ACCORDANCE WITH

CONTRACT REQUIREMENTS AND AS DIRECTED BY COMPANY. IT SHALL BE
INSTALLED TO THE LEFT OF THE PIPE CENTER LINE VIEWING IN THE DIRECTION OF
FLOW AT 300 MM FROM THE PIPE LINE OD AND THE WARNING SIGN PLATE SHALL
FACE THE UTILITY BEING CROSSED.
B.
THE WARNING SIGN PLATE MAY BE MOUNTED ON VENT PIPES OR KM POSTS

WHEREVER FEASIBLE.
4. MATERIAL FOR MARKERS SHALL BE:
PLATE
IS 2062 Gr. A
PIPE
IS-1239
5. FOR FLUIDS COVERED BY ASME B 31.8, MENTION GAS IN LOCATION - - -. FOR FLUIDS
COVERED BY ASME B 31.4, MENTION PETROLEUM AND OTHER FLUIDS, MENTION THE NAME
OF THE FLUID.
6. THE FOUNDATION SHALL BE MADE OF CONCRETE M20.
7. IN CASE THE WARNING SIGN IS TO BE USED WHERE THE PIPE LINE CROSSES A HAZARDOUS
FACILITY LIKE A H.T CABLE OR ANOTHER PETROLEUM / GAS PIPE LINE, THEN THE WARNING
SIGN SHALL READ HIGH PRESSURE GAS PIPE LINE CROSSING H.T CABLE (OR THE
CONCERNED FACILITY) IN LETTERS OF SIZE AS DECIDED BY COMPANY.
8. SIGN PLATE IN REGIONAL LANGUAGE SHALL BE PREPARED BY CONTRACTOR ON SMALLER LINES
AND GET APPROVED BY COMPANY.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-018
REV-0
Page 3 of 3
GAIL (INDIA) LTD

NEW DELHI
PIPE LINE ROAD / HIGHWAY CASED

CROSSING
DOCUMENT NO.
S-04-01-020
REV-0
Page 1 of 2
NOTES:
2. REFER API 1102
REQUIREMENTS.
(LATEST
EDITION)
FOR
OTHER
DESIGN
AND
INSTALLATION
3. FOR CASING PIPE DETAILS, REFER SCOPE OF WORK AND SOR.

4. AT EACH CROSSING, PIPE LINE CROSSING WARNING SIGN SHALL BE INSTALLED ON EITHER
SIDE OF THE CROSSING. THE WARNING PLATE MAY BE MOUNTED ON VENT PIPE.
5. CATHODIC PROTECTION TEST LEAD TERMINAL BOX MAY BE MOUNTED ON VENT PIPE. FOR
CP LEAD TERMINAL BOX DETAILS, REFER RELEVENT STANDARD.
6. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS
OF EACH CROSSING AND PREPARE DETAILED DRAWINGS FOR INDIVIDUAL CROSSING FOR
COMPANY / CONCERNED AUTHORITIES APPROVAL BEFORE COMMENCEMENT OF
CONSTRICTION.
7. ALL PIPELINE JOINTS SHALL BE RADIOGRAPHED.
8. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH
SUITABLE MEGGER.
9. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE ROAD SHALL BE RESTORED TO
THE SATISFACTION OF COMPANY / CONCERNED ROAD AUTHORITIES.
10. PIPELINE SECTION SHALL BE PRETESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN
LINE TESTING WHEN REQUIRED BY CONCERNED AUTHORITIES / COMPANY.
11. ANGLE OF INTERSECTION BETWEEN PIPE LINE AND THE ROAD / HISGHWAY SHALL BE AS
CLOSE TO 900 AS POSSIBLE, BUT IN NO CASE LESS THAN 300.
12. JACKING / BORE THRU TECHNIQUE SHALL BE USED FOR THE CROSSING UNLESS SPECIFIED
OTHERWISE.
13. FOR VENT, DRAIN AND CASING PIPE DETAILS, REFER RELEVENT SPECIFICATIONS /
DRAWINGS / STANDARDS.
GAIL (INDIA) LTD

NEW DELHI
PIPE LINE ROAD / HIGHWAY CASED

CROSSING
DOCUMENT NO.
S-04-01-020
REV-0
Page 2 of 2
NOTES:
1. ALL DIMENSIONS ARE IN mm, UNLESS SPECIFIED OTHERWISE.
2. SINGLE SAG CROSSING SHALL NORMALLY BE USED WHERE THERE IS NO EVIDENCE OF EROSION
OF BANKS AND SCOURING OR SHIFTING OF STREAM BOITOM AND WHERE BED WIDTH DOES
NOT PROHIBIT ITS USE.
3. DOUBLE SAG CROSSING SHALL BE USED WHERE THERE IS EVIDENCE OF EROSION OF BANKS,
SCOURING OR SHIFTING OF STREAM BOTTOM.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TYPICAL STREAM CROSSING
S-04-01-021
REV-0
Page 1 of 2
4. IN DOUBLE SAG CROSSING, GENERALLY COLD FIELD BENDS SHALL BE USED. USE OF FACTORY
MADE R=6D BENDS SHALL BE MINIMIZED. R=6D BENDS SHALL BE USED ONLY WITH PRIOR
APPROVAL OF COMPANY.
5. UNLESS OTHERWISE SPECIFIED, THE MINIMUM COVER OVER THE PIPE MEASURED BELOW THE
LOWEST BED LEVEL SHALL BE 1500 MM.
6. THE TYPE AND EXTENT OF BUOYANCY CONTROL MEASURES SHALL BE AS PER SPECIFICATION
AND AS DIRECTED BY COMPANY FOR INDIVIDUAL CROSSING AND SHALL BE SHOWN ON THE
AUGNMENT SHEETS.
7. THE FILL AT THE BANKS SHALL BE TAMPED FIRMLY AND REINFORCED WITH SACKED EARTH,
LEAN CONCRETE, RIP RAP OR BY OTHER MEANS AS DIRECTED BY COMPANY. ADDITIONAL BANK
PROTECTION MEASURES AS PER SPECIFICATIONS SHALL BE ADOPTED WHEN THERE IS
EVIDENCE OF EROSION AND SLUMPING OF BANKS OR WHEN THE BANKS ARE STEEP.
8. THE LOCATON OF CROSSING SWLL BE IN A LONG STRAIGHT STRDCH OF THE STREAM IF
POSSIBLE.
9. EXACT POSITION AND ANGLE OF COLD BENDS SHALL BE DETERMINED IN FIELD.
10. AFER INSTALLATION OF THE CROSSING, THE WATER COURSE SHALL BE RESTORED TO ITS
ORIGINAL CONDITION TO THE ENTIRE SATISFACTION OF THE AUTHORITIES HAVING
JURISDICTION OVER THE SAME. WHERE THE EXCAVATED MATERIAL IS UNSUITABLE, TRENCH
SHALL BE BACKFILLED WITH MATERIAL APPROVED BY COMPANY.
11. WIDTH OF CROSSING SHALL BE THAT CORRESPONDING TO THE HIGHEST WATER LEVEL. THE
HIGHEST WATER LEVEL SHALL BE DETERMINED BASED ON THE FOLLOWING:
(i)
HISTORICAL RECORDS (TO THE EXTENT AVAILABLE)
(ii)
BANK CONDITION VIS-A-VIS EROSION, ETC.
(iii)
EVIDENCE OF EXTINCTION OF VEGITATION ALONG BANKS.
(iv)
DISCUSSIONS WITH LOCAL PEOPLE.
12. THE NUMBER OF WARNING SIGNS SHALL BE

a.
1 (ONE) FOR CROSSINGS LESS THAN 15 M WIDTH AT UP STREAM BANK
b.
2 (TWO) FOR CROSSINGS ABOVE 15 M WIDTH.
13. STRAIGHT LENGTH OF PIPE SHALL BE USED AT LEAST FOR THE ENTIRE WIDTH OF CROSSING.
14. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR
EACH CROSSING AND WHEN DIRECTED BY COMPANY, CONTRACTOR SHALL PREPARE DETAILED
DRAWINGS FOR INDIVIDUAL CROSSINGS FOR COMPANY APPROVAL BEFORE COMMENCEMENT OF
CONSTRUCTION.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TYPICAL STREAM CROSSING
S-04-01-021
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TYPICAL SLOPE BREAKER DETAILS
S-04-01-022
REV-0
Page 1 of 3
NOTES:
2. SLOPE BREAKER BAGS TO BE GUNNY BAGS FILLED WITH 10:1 SAND:PORTLAND CEMENT MIXTURE.
3. HIGHEST SLOPE BREAKER TO BE PLACED 2.0 M FROM THE OVER-BEND AND THE LOWEST SLOPE BREAKERS TO BE PLACED 2.0 M FROM THE SAG BEND.
4. DISTANCE L BETWEEN BREAKERS AND NUMBER OF LAYERS OF BAGS (IN VERTICAL DIRECTION) FOR SLOPE BREAKER SHALL BE DECIDED ON CASE TO
CASE BASIS DEPENDING UPON SLOPE OF THE GROUND AND CHARACTERSTICS OF SOIL BAGS. BAGS SHALL BE PLACED IN SUCH A MANNER SO AS TO HAVE A
STABLE ARRANGEMENT. HOWEVER, DISTANCE L SHALL NOT EXCEED 7 M.
5. BAGS TO BE PLACED VERTICAL IN THE TRENCH AND NOT IN 900 TO THE PLANE OF PIPE.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-022
REV-0
Page 2 of 3
6. BREAKERS SHALL BE INSTALLED IN STEEP SLOPE AREAS (GENERALLY SLOPE 10% OR MORE) AS SHOWN IN DRAWINGS AND WHEREVER INSTRUCTED BY
ENGINEER-IN-CHARGE.
7. TOP LAYER OF TRENCH SHALL BE BACKFILLED WITH SOIL OR CRUSHED ROCK (EXCAVATED MATERIAL).
8. THE REMAINING TRENCH AREA SHALL BE BACKFILLED AS REQUIRED.
9. WHERE ROCK, GRAVEL, LUMPS OF HARD SOIL OR LIKE MATERIALS ARE ENCOUNTERED, SELECT BACKFILL MATERIALS LIKE SOIL, CLAY OR OTHER
MATERIALS CONTAINING NO GRAVEL, ROCK OR LUMPS OF HARD SOIL SHALL BE PLACED AROUND THE PIPE.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-022
REV-0
Page 3 of 3
GAIL (INDIA) LTD

NEW DELHI
BANK PROTECTION DETAILS FOR

WATER CROSSINGS
DOCUMENT NO.
S-04-01-023
REV-0
Page 1 of 3
GAIL (INDIA) LTD

NEW DELHI

WATER CROSSINGS
DOCUMENT NO.
S-04-01-023
REV-0
Page 2 of 3
NOTES:
1. ALL DIMENSIONS ARE IN MM.
2. MATTRESSES SHALL BE INSTALLED AFTER COMPLETION OF GRADING.
3. IF MORE THAN ONE MATTRESSIS USED, ADJACENT MATTRESSES SHALL BE LACED
TOGETHER.
4. DIMENSIONS X SHALL BE 2 M OR 10 M AS PER STANDARD SPECIFICATIONS S-04-02-026
AND S-04-02-027.
INSTALLATION PROCEDURE:
1. OPEN MESH BUNDLE AND STRETCH OUT BASE PANEL.
2. LACE TOGETHER THE SIDE, END PANELS AND DIAPHRAGM.
3. FILL WITH GRADED STONES OF 75-150 MM
4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS.
5. ANCHOR THE TOP MATTRESS.
GAIL (INDIA) LTD
NEW DELHI

WATER CROSSINGS
DOCUMENT NO.
S-04-01-023
REV-0
Page 3 of 3
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TYPICAL DETAILS OF RAILWAY CROSSING
S-04-01-024
REV-0
Page 1 of 3
NOTES:
2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. FOR CP LEAD TERMINAL BOX DETAILS REFER RELEVANT STD./
SPECIFICATION.
3. AT EACH CROSSING, A PIPELINE WARNING SIGN SHALL BE INSTALLED ON EITHER SIDE OF CROSSING. WARNING SIGN PLATE MAY BE MOUNTED ON THE
VENT PIPE.
4. REFER API RP 1102 FOR OTHER DESIGN AND INSTALLATION REQUIREMENTS.
5. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH SUITABLE MEGGER.
6. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE AREA SHALL BE RESTORED TO THE SATISFACTION OF THECONCERNED AUTHORITIES/COMPANY.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-024
REV-0
Page 2 of 3
7. CASING PIPE SHALL BE AS PER SCOPE OF WORK AND SOR.

8. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR EACH CROSSING AND PREPARE DETAILED DRAWINGS FOR
COMPANY'S / CONCERNED AUTHORITY'S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
9. PIPELINE SECTION SHALL BE PRE-TESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN LINE TESTING WHEN REQUIRED BY THE AUTHORITIES
CONCERNED AND/OR AS DIRECTED BY THE COMPANY.
10. ANGLE OF INTERSECTION BETWEEN PIPELINE AND RAILWAY SHALL BE AS CLOSE TO 900 AS POSSIBLE BUT IN NO CASE LESS THAN 850.
11. CASING PIPE SHALL BE EXTENDED FOR A DISTANCE OF UPTO 14.00m FROM CENTRE LINE OF OUTERMOST RAILWAY TRACK OR 0.6m BEYOND RAILWAY ROW
LIMITS ON EITHER SIDE, WHICHEVER IS MORE.
12. JACKING / BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING.
13. SEPARATE C.S. CONDUIT FOR OFC SHALL BE INSTALLED AT MINIMUM DISTANCE FROM CASING FOR CARRIER PIPE, IF SPECIFIED.
14. ALL CARRIER PIPE JOINTS SHALL BE RADIOGRAPHED.
15. COATING OF CASING PIPE SHALL BE AS PER REQUIREMENT OF AUTHORITIES.
16. FOR VENT, DRAIN, CASING PIPE, INSULATORS, INSULATOR SPACING, CASING END SEASL ETC. REFER RELEVENT STANDARDS (S-04-01-007 & S-04-01-008)
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
S-04-01-024
REV-0
Page 3 of 3
NOTES:
1. ALL DIMENSIONS ARE IN MM.
2. SELECT BACK FILL MUST HAVE MIN. AS PLACED DRY DENSITY OF 1800 KG/M3. IF FOUND
NECESSARY IN FIELD, THE SELECT BACK FILL SHALL BE COMPACTD TO ACHIEVE A DRY
DENSITY OF MIN. 1800 KG/M3.
GAIL (INDIA) LTD

NEW DELHI
SELECT BACK FILL FOR STATION

APPROACH
DOCUMENT NO.
S-04-01-026
REV-0
Page 1 of 2
3. MINIMUM PIPE LINE COVER SHALL BE 1000 MM. ANY EXTRA COVER REQUIREMENT SHALL BE
IN ACCORDANCE WITH SPECIFICATIONS / STANDARDS / DRAWINGS.
4. MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED
AUTHORITIES WHEREVER REQUIRED.
5. FOR MINIMUM COVER REQUIREMENT AT PIPELINE CROSSING ROADS, RAILWAY TRACKS,
RIVERS, MARSHY AREAS ETC. REFER GAIL STANDARDS / DRAWINGS.
6. TRENCH CROSS SECTION SHALL BE VIEWED IN DIRECTION OF FLOW.
GAIL (INDIA) LTD

NEW DELHI
SELECT BACK FILL FOR STATION

APPROACH
DOCUMENT NO.
S-04-01-026
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
SLOPE STABILIZATION IN GHAT /

HILL AREAS
DOCUMENT NO.
S-04-01-027
REV-0
Page 1 of 2
NOTES:
2. FOR ALL PIPELINES TO BE CONSTRUCTED IN THE LAND, MINIMUM COVER SHALL BE 1000
MM. ANY EXTRA COVER REQUIREMENT SHALL BE IN ACCORDANCE WITH SPECIFICATIONS /
STANDARDS / DRAWINGS.
3. MINIMUM COVER REQUIREMENT SHALL BE SUBJECT TO APPROVAL OF CONCERNED
AUTHORITIES WHEREVER REQUIRED.
4. FOR MINIMUM COVER REQUIREMENT AT PIPELINE CROSSING ROADS, RAILWAY TRACKS,
WATER BODIES, MARSHY AREAS ETC. REFER GAIL STANDARDS.
5. SUITABLE DRAIN SHALL BE PROVIDED PARALLEL, ALL ALONG THE PIPE LINE TRENCH AND
ACROSS AT EVERY 250 M.
GAIL (INDIA) LTD

NEW DELHI
SLOPE STABILIZATION IN GHAT /

HILL AREAS
DOCUMENT NO.
S-04-01-027
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
SOIL STABILIZATION IN HILLY

AREAS
DOCUMENT NO.
S-04-01-028
REV-0
Page 1 of 3
GAIL (INDIA) LTD

NEW DELHI

AREAS
DOCUMENT NO.
S-04-01-028
REV-0
Page 2 of 3
NOTES:
2. MATTRESSES SHALL BE INSTALLED AFTER COMPLETION OF GRADING.
3. IF MORE THAN ONE MATTRESSIS USED, ADJACENT MATTRESSES SHALL BE LACED
TOGETHER.
1. OPEN MESH BUNDLE AND STRETCH OUT BASE PANEL.
2. LACE TOGETHER THE SIDE, END PANELS AND DIAPHRAGM.
3. FILL WITH GRADED STONES OF 75-150 MM
4. LACE TOP PANEL TO THE SIDE AND END PANELS AND DIAPHRAGMS.
5. ANCHOR THE TOP MATTRESS.
GAIL (INDIA) LTD

NEW DELHI

AREAS
DOCUMENT NO.
S-04-01-028
REV-0
Page 3 of 3
NOTES:
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED.
2. CATHODIC PROTECTION TEST LEADS TERMINAL BOX MAY BE MOUNTED ON THE VENT PIPE. THE
NUMBER OF WARNING SIGNS SHALL BE:
a.
b.
1 (ONE) FOR CROSSINGS LESS THAN 15 M WIDTH.

3. FOR SYMBOLS, TRENCH DIMENSIONS, ROW DETAILS, MARKER ETC. REFER RELEVANT JOB
STANDARDS.
4. ELECTRICAL INSULATION BETWEEN CASING AND CARRIER PIPES SHALL BE CHECKED WITH
SUITABLE MEGGER.
5. AFTER INSTALLATION OF CASING AND CARRIER PIPES, THE CANAL SHALL BE RESTORED TO THE
SATISFACTION OF THE CONCERNED AUTHORITIES/COMPANY.
6. CASING PIPE SHALL BE AS PER SCOPE OF WORK AND SOR.
7. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONS WITH RESPECT TO SURVEY DETAILS FOR
EACH CANAL CROSSED AND PREPARE DETAILED DRAWINGS FOR COMPANY'S / CONCERNED
AUTHORITY'S APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
8. PIPELINE SECTION SHALL BE PRE-TESTED HYDROSTATICALLY, SEPARATELY FROM THE MAIN
LINE TESTING WHEN REQUIRED BY THE CONCERNED AUTHORITIES AND/OR AS DIRECTED BY
THE COMPANY REPRESENTATIVE.
9. SEPARATE CASING PIPES SHALL BE INSTALLED FOR OFC AT MINIMUM DISTANCE FROM CASING
FOR CARRIER PIPE, IF SPECIFIED.
GAIL (INDIA) LTD
NEW DELHI
TYPICAL LINED CANAL CASED

CROSSING DETAIL
DOCUMENT NO.
S-04-01-029
REV-0
Page 1 of 2
10. JACKING/BORE THRU' TECHNIQUE SHALL BE USED FOR THE CROSSING.

11. ALL PIPELINE JOINTS SHALL BE RADIOGRAPHED.
12. FOR DRAIN, VENT, CASING PIPE, INSULATOR, INSULATOR SPACING, END SEALS ETC. REFER
RELEVENT STANDARD / SPECIFICATIONS.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL LINED CANAL CASED

CROSSING DETAIL
DOCUMENT NO.
S-04-01-029
REV-0
Page 2 of 2
NOTES:
2. CANAL CROSSING SHALL BE RESTORED TO ORIGINAL CONDITION TO THE
SATISFACTION OF COMPANY AND CONCERNED AUTHORITIES HAVING JURISDICTION.
ENTIRE
3. THE NUMBER OF WARNING SIGNS SHALL BE:

a.
b.
1 (ONE) FOR CROSSING LESS THAN 15 M WIDTH.

4. FOR SYMBOLS, TRENCH DIMENSIONS, ROW DETAILS, MARKERS ETC. REFER RELEVENT JOB
STANDARDS.
5. ANGLE OF INTERSECTION BETWEEN PIPELINE AND THE CANAL SHALL BE AS CLOSE TO 900 AS
POSSIBLE IN NO CASE LESS THAN 300.
6. IN CASE PIPELINE COATING IS LIABLE TO DAMAGE WHILE BORING / JACKING, A PROTECTIVE
COATING OVER CORROSION COATING OF SUITABLE MATERIAL (APPROVED BY COMPANY) SHALL
BE PROVIDED AS DIRECTED BY ENGINEER-IN-CHARGE.
7. CONTRACTOR SHALL VERIFY THE ACTUAL DIMENSIONSWITH RESPECT TO SURVEY DETAILS FOR
EACH CANAL CROSSED AND PREPARE DETAILED DRAWINGS FOR COMPANYS / CONCERNED
AUTHORITYS APPROVAL BEFORE COMMENCEMENT OF CONSTRUCTION.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL LINED CANAL UNCASED

CROSSING DETAIL
DOCUMENT NO.
S-04-01-030
REV-0
Page 1 of 1
NOTES:
2. A DRAIN SHALL BE PROVIDED TO DRAIN OFF WATER FROM ROU. THIS DRAIN SHALL BE
CONNECTED TO THE NEAREST STREAM/NALA. CROSS DRAINS SHALL ALSO BE PROVIDED AT
SUITABLE LOCATIONS AS PER INSTRUCTIONS OF ENGINEER-IN-CHARGE.
3. WHENEVER THE PIPELINE IS CROSSING ANY STREAM/ NALA, ENTIRE WIDTH OF SUCH STREAM/
NALA SHALL BE PROVIDED WITH A MINIMUM 100 MM THICK LAYER OF PCC TO PREVENT SOIL
WASH OFF DURING RAINS. THE PCC LAYER SHALL COVER THE ENTIRE WIDTH OF PREPARED
ROU.
4. REFER APPLICABLE STANDARD/ DRAWINGS FOR DETAILS OF OFC.
5. FOR TRENCH DETAILS REFER STD. NO. S-04-01-002.
6. THE BACKFILLING OF THE TRENCH AND OTHER TRENCH STABILIZATION MEASURES SHALL BE AS
INDICATED IN APPROVED FOR CONSTRUCTION ALIGNMMENT SHEETS OR AS DIRECTED BY
ENGINEER-IN-CHARGE.
7. RESTORATION OF ROU SHALL BE CARRIED OUT AS PER THE INSTRUCTIONS OF ENGINEER-INCHARGE.
GAIL (INDIA) LTD

NEW DELHI
TYPICAL CROSS SECTION FOR ROU

PREPARATION IN HILL AREAS
DOCUMENT NO.
S-04-01-031
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
JACK SCREW FOR SPECTACLE BLIND

FIG 8 (150#, 300#, 600# RF)
STANDARD
S-05-01-001
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
JACK SCREW FOR SPACERS AND

BLINDS (150#, 300#, 600# RF)
STANDARD
S-05-01-002
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
VENTS AND DRAINS (ON LINES 1-1/2

AND BELOW)
STANDARD
S-05-01-003
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
VENTS AND DRAINS (ON LINES 2

AND ABOVE)
STANDARD
S-05-01-004
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
WELLS INSTALLATION 1-1/2 DIA

TAPS
STANDARD
S-05-01-005
REV-0
Page 1 of 2
GAIL (INDIA) LTD

NEW DELHI
WELLS INSTALLATION 1-1/2 DIA

TAPS
STANDARD
S-05-01-005
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
PRESSURE TAPPING (PA, PG, PC, PT,

PIC ETC)
STANDARD
S-05-01-006
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
DIMESIONS FOR HANDLE PROJECTION

FOR SPACERS AND BLINDS: 24 NB
(150#, 300#, 600# FF)
SPECIFICATION
S-05-01-007
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
T STRAINER TYPE-1 2 4
(150# RF, 300# RF AND RTJ, 600# RF AND RTJ)
SPECIFICATION
S-05-01-008
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
T STRAINER TYPE-1 6 24
(150# RF, 300# RF AND RTJ, 600# RF AND RTJ)
SPECIFICATION
S-05-01-009
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
ORIENTATION OF ORIFICE TAPS
S-05-01-010
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
STUB-IN STANDARD
S-05-01-011
REV-0
Page 1 of 2
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
STUB-IN STANDARD
S-05-01-011
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
WELDING OF PIPEWITH DIFFERENT

THICKNESS
DOCUMENT NO.
S-05-01-012
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
FILLET WELD DETAILS
S-05-01-013
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
WELDING DETAILS FOR BRANCH

CONNECTION
DOCUMENT NO.
S-05-01-014
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
METHOD OF CUTTING AND

DIMENSIONS OF FIELD
MANUFACTURED CONCENTRIC
REDUCERS
DOCUMENT NO.
S-05-01-015
REV-0
Page 1 of 1
NOTES:
A. 3 MM MAX. FROM INDICATED DIMENSIONS FOR FACE TO FACE, CENTER TO FACE LOCATION OF
THE ATTACHMENTS ETC. TOLERENCE CAN NOT BE ADDED.
B. 1.5 MM MAX. LATERAL TRANSLATION IN ANY DIRECTION FROM THE INDICATED POSITION.
C. 1.5 MM MAX. ROTATION FROM THE INDICATED POSITION, MEASURED AS SHOWN.
D. 1 MM MAX. OUT OF ALIGNMENT FROM THE INDICATED POSITION MEASURED ACROSS ANY
DIAMETER AS SHOWN.
GAIL (INDIA) LTD
NEW DELHI
DOCUMENT NO.
TOLERENCE FOR FABRICATION
S-05-01-016
REV-0
Page 1 of 2
E. FLATTENING, MESAURED AS DIFFERENCE BETWEEN MAX. AND MIN. OD AT ANY CROSS SECTION.
-3% MAX. FOR PIPE WITH EXTERNAL PRESSURE.
8% MAX. FOR PIPE WITH INTERNAL PRESSURE.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
TOLERENCE FOR FABRICATION
S-05-01-016
REV-0
Page 2 of 2
MATERIAL:
SHOE
INSULATION THK.
UP TO 75
76 TO 125
126 TO 175
GUIDE PLATE: IS 2062
GAIL (INDIA) LTD

NEW DELHI
H
100
150
200
SHOE SIZE
A
B
C
CUT FROM ISMB

200
300
400
PIPE SHOE FOR HOT INSULATED CS

PIPE , SIZE 2 THRU 8 TYPE - S1 (FOR
TEMP.UPTO 3430C)
X
44
46
49
DOCUMENT NO.
S-05-01-017
REV-0
Page 1 of 2
MAXIMUM ALLOWABLE LOAD ON FILLET WELD OF RESTRAINT (KG/CM)

TEMPERATURE IN DEG C
WELD SIZE (MM)
200
250
300
6
340
250
220
8
450
340
300
10
560
420
370
350
200
270
330
NOTE:
1. LOADS ON FILLET WELDS OF GUIDE / CROSS GUIDE / ANCHOR SHALL BE LIMITED TO VALUES
TABULATED ABOVE AGAINST VARIOUS TEMPERATURES, FOR RESPECTIVE WELD SIZE, RUNNING
LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2. SHOE LENGTH SHALL BE TAKEN AS 300 MM FOR FIG. 1,2,3 AND 6 AND 400 MM FOR FIG. 4 AND
5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1, 2 OR 3, FOR AXIAL MOVEMENTS EXCEEDING 100
MM, SHOE LENGTH SHALL BE INCREASED ACCORDINGLY.
3. FOR FIG. 3 & 4, IF THE REQUIRED GUIDE GAP IS MORE THAN 3 MM, THE DIMENSIONS OF GUIDE
PLATE SHALL BE SUITABLY MODIFIED.
4. GUIDE PLATES SHALL BE WELDED ON BOTH SIDES.
5. FOR CROSS GUIDES IN FIG. 4 & 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH.
6. IN CASE OF BEAM TYPE SUPPORTED STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS
SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON SIZE OF THE SUPPORTING STEEL
MEMBER.
7. LONGITUDINAL PIPE MOVEMENT NOT TO EXCEED 150 MM AND SHOE LENGTH NOT TO EXCEED
400 MM.
GAIL (INDIA) LTD

NEW DELHI

PIPE , SIZE 2 THRU 8 TYPE - S1 (FOR
TEMP.UPTO 3430C)
DOCUMENT NO.
S-05-01-017
REV-0
Page 2 of 2
Note:
1. LOADS ON FILLET WELD OF GUIDES / CROSS-GUIDE / ANCHOR SHALL BE LIMITED TO THE
VALUES TABULATED AGAINST VARIOUS TEMPERATURES FOR THE RESPECTICE WELD SIZE, FOR
RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE
TEMPERATURES.
2. SHOE LENGTH SHALL BE TAKEN AS 300MM FOR FIG. 1,2,3 AND 6 AND AS 400MM FOR FIG. 4 AND
5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1,2 OR 3, FOR AXIAL MOVEMENT EXCEEDING
100MM, SHOE LENGTH SHALL BE INCREASED CORRESPONDINGLY.
GAIL (INDIA) LTD

NEW DELHI

PIPE , SIZE 10 THRU 30 TYPE S2
(FOR TEMP.UPTO 3430C)
DOCUMENT NO.
S-05-01-018
REV-0
Page 1 of 2
3. FOR FIG. 3 AND 4, IF THE REQUIRED GUIDE-GAP IS MORE THAN 3MM, DIMENSIONS OF THE
GUIDE PLATE SHALL BE SUITABLE MODIFIED.
4. GUIDEPLATES SHALL BE WELDED ON BOTH SIDES.
5. FOR CROSS GUIDE IN FIG. 4 AND 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH.
6. IN CASE OF BEAM TYPE OF SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS
SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL
BEAM.
7. FOR FIG. 4 AND 5, IF THE VERTICALMOVEMENT IS 15MM, PROVIDE 3 NO.S OF GUSSET PLATES
(IS-2062) EQUALLY SPACED.
8. LONGITUDINAL PIPE MOVEMENT NOTTO EXCEED 150MM AND SHOE LENGTH NOT TO EXCEED
400MM.
9. PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS THAT
OF LINE PIPE OR 12MM, WHICHEVER IS LESS.
GAIL (INDIA) LTD

NEW DELHI

PIPE , SIZE 10 THRU 30 TYPE S2
(FOR TEMP.UPTO 3430C)
DOCUMENT NO.
S-05-01-018
REV-0
Page 2 of 2
MAXIMUM ALLOWABLE LOAD ON FILLET WELD OF RESTRAINT (KG/CM)

TEMPERATURE IN DEG C
WELD SIZE (MM)
200
250
300
6
340
250
220
8
450
340
300
10
560
420
370
GAIL (INDIA) LTD

NEW DELHI
PIPE SADDLE FOR CS BARE PIPE, SIZE

14 THRU 48, TYPE S6A
(FOR TEMP. UP TO 3430C)
350
200
270
330
DOCUMENT NO.
S-05-01-019
REV-0
Page 1 of 2
NOTE:
1. LOADS ON FILLET WELDS OF GUIDE / CROSS GUIDE / ANCHOR SHALL BE LIMITED TO VALUES
TABULATED ABOVE AGAINST VARIOUS TEMPERATURES, FOR RESPECTIVE WELD SIZE, RUNNING
LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2. IN CASE THE PIPE SCHEDULE IS NOT THE SAME AS TABULATED ABOVE, THE DIMENSIONS A
AND h SHALL BE MODIFIED ACCORDINGLY.
EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE
PIPE OR 12 MM WHICHEVER IS LESS.
4. GUIDE PLATES SHALL BE OF IS-2062. THEY SHALL BE WELDED ON BOTH SIDES.
5. IN CASE OF SIZE REDUCTION (S) IN STRAIGHT RUN WITH BOP, PROTECTION SHIELS THICKNESS
FOR ALL SIZES SHALL BE EQUAL TO THAT FOR THE LARGEST DIAMETER PIPE.
GAIL (INDIA) LTD

NEW DELHI
PIPE SADDLE FOR CS BARE PIPE, SIZE

14 THRU 48, TYPE S6A
DOCUMENT NO.
S-05-01-019
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
PIPE SHOE FOR HOT INSULATION

EXCEEDING 175MM / SLOPE LINE
PIPE, SIZE 2 THRU 6
TYPE S9A / S9B / S9C
DOCUMENT NO.
S-05-01-020
REV-0
Page 1 of 2
Note:
1. LOADS ON FILLET WELD OF GUIDES / CROSS-GUIDE / ANCHOR SHALL BE LIMITED TO THE
VALUES TABULATED AGAINST VARIOUS TEMPERATURES FOR THE RESPECTICE WELD SIZE, FOR
RUNNING LENGTH OF WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE
TEMPERATURES.
2. SHOE LENGTH SHALL BE TAKEN AS 300MM FOR FIG. 1,2,3 AND 6 AND AS 400MM FOR FIG. 4 AND
5, UNLESS SPECIFIED OTHERWISE. FOR FIG. 1,2 OR 3, FOR AXIAL MOVEMENT EXCEEDING
100MM, SHOE LENGTH SHALL BE INCREASED CORRESPONDINGLY.
3. FOR FIG. 3 AND 4, IF THE REQUIRED GUIDE-GAP IS MORE THAN 3MM, DIMENSIONS OF THE
GUIDE PLATE SHALL BE SUITABLE MODIFIED.
4. GUIDEPLATES SHALL BE WELDED ON BOTH SIDES.
5. FOR CROSS GUIDE IN FIG. 4 AND 5, LENGTH OF ANGLE SHALL BE SAME AS SHOE WIDTH.
6. IN CASE OF BEAM TYPE OF SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS
SHOWN IN FIG. 5. HEIGHT OF PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL
BEAM.
7. LONGITUDINAL PIPE MOVEMENT NOTTO EXCEED 150MM AND SHOE LENGTH NOT TO EXCEED
400MM.
EQUIVALENT TO THAT OF PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS THAT
OF LINE PIPE OR 12MM, WHICHEVER IS LESS.
GAIL (INDIA) LTD

NEW DELHI
PIPE SHOE FOR HOT INSULATION

EXCEEDING 175MM / SLOPE LINE
PIPE, SIZE 2 THRU 6
TYPE S9A / S9B / S9C
DOCUMENT NO.
S-05-01-020
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
LOW SUPPORT SLIDING FOR BARE

AND INSULATED PIPE, SIZE 2 THRU
36 TYPE L1 AND L1A
DOCUMENT NO.
S-05-01-021
REV-0
Page 1 of 2
NOTE:
1. INSERT AND SLIDING PLATE MATERIAL SHALL BE CARBON STEEL WHER TEMP. IS 4000C WITH
h 200 MM. SLIDING PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL.
2. DIMENSION M LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE STUB
MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL
BE CARBON STEEL. MINIMUM VALUE OF M SHALL BE INSULATION THICKNESS + 25 MM.
A.
B.
FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CS I.E. M=0.
FOR ALLOY STEEL / STAINLESS STEEL LINE PIPE, SUPPORT PIPE SHALL CONSIST OF
THE FOLLOWING:
FOR h 500 MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUIVALENT TO

THAT OF LINE PIPE I.E. M = h.
FOR h > 500 MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M =
INSULATION THICKNESS + 25 MM OR 100 MM WHICHEVER IS GREATER.
3. IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN THE TABLE IS NOT
AVAILABLE USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THICKNESS AVAILABLE.
4. PROTECTION SHIELD (LENGTH = K MM) CUT FROM LINE PIPE OR EQUIVALENT PLATE SHALL BE
PROVIDED ON HORIZONTAL LINE AS FOLLOWS:
A.
FOR CLASS #150 & #300 PIPING:

CS & AS LINES SS LINES
-
B.
10 AND ABOVE
2 AND ABOVE
FOR CLASS #600 AND HIGHER

CS, AS AND SS -
10 AND ABOVE
5. DIMENSION C IS TO BE MODIFIED IF OTHER THAN R=1.5D ELBOWS ARE USED.

6. IN CASE CLACULATED h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE RAISED
ACCORDINGLY.
GAIL (INDIA) LTD

NEW DELHI

36 TYPE L1 AND L1A
DOCUMENT NO.
S-05-01-021
REV-0
Page 2 of 2
NOTE:
1.
FOR THE APPLICABLE SIZE NOS., DIMENSIONS TABLE AND NOTES, REFER GAIL STANDARD
S-05-01-021.
2.
REFER VIEW A-A OF GAIL STANDARD S-05-01-021.
GAIL (INDIA) LTD

NEW DELHI
LOW SUPPORT FIXED FOR BARE AND

INSULATED PIPE, SIZE 2 THRU 36
TYPE L3 AND L3A
DOCUMENT NO.
S-05-01-022
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI

PIPE SIZE 3/4 THRU 36, TYPE L5
AND L5A (FOR TEMP. UP TO 4000C)
DOCUMENT NO.
S-05-01-023
REV-0
Page 1 of 1
NOTE:
1.
WELDED ATTACHEMENT (6MM THICK) REQUIRED ONLY IN CASE OF STAINLESSSTEEL / ALLOY STEEL LINE PIPE. MATERIAL OF WELDED ATTACHMENT SHALL BE
SAME AS THAT OF LINE PIPE.
GAIL (INDIA) LTD

NEW DELHI

36, TYPE L6
DOCUMENT NO.
S-05-01-024
REV-0
Page 1 of 2
2.
PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR EQUIVALENT PLATE AND
SHALL BE AS PER VIEW A-A OF GAIL STANDARD S-05-01-021.
3.
FOR LINE TEMPERATURES UP TO 4000C, CONNECTING PLATE SHALL BE CARBON

STEEL. FOR HIGHER TEMPERATURES IT SHALL BE SAME AS THAT OF LINE PIPE.
4.
IN CASE CALCULATED H/h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE

RAISED ACCORDINGLY.
GAIL (INDIA) LTD

NEW DELHI

36, TYPE L6
DOCUMENT NO.
S-05-01-024
REV-0
Page 2 of 2
(PLEASE REFER NOTES MENTIONED IN NEXT PAGE)
GAIL (INDIA) LTD

NEW DELHI
LOW SUPPORT FIXED / RESTRAINED

FOR BARE AND INSULATED PIPE,
SIZE 2 THRU 36, TYPE L7 AND
L7A
DOCUMENT NO.
S-05-01-025
REV-0
Page 1 of 3
NOTE:
1.
WELDED ATTACHEMENT (6MM THICK) REQUIRED ONLY IN CASE OF STAINLESSSTEEL / ALLOY STEEL LINE PIPE. MATERIAL OF WELDED ATTACHMENT SHALL BE
SAME AS THAT OF LINE PIPE.
GAIL (INDIA) LTD

NEW DELHI

L7A
DOCUMENT NO.
S-05-01-025
REV-0
Page 2 of 3
2.
PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR EQUIVALENT PLATE AND
SHALL BE AS PER VIEW A-A OF GAIL STANDARD S-05-01-021.
3.
FOR LINE TEMPERATURES UP TO 4000C, CONNECTING PLATE SHALL BE CARBON

STEEL. FOR HIGHER TEMPERATURES IT SHALL BE SAME AS THAT OF LINE PIPE.
4.
IN CASE CALCULATED H/h EXCEEDS THE MAXIMUM VALUE, PEDESTAL SHALL BE

RAISED ACCORDINGLY.
GAIL (INDIA) LTD

NEW DELHI

L7A
DOCUMENT NO.
S-05-01-025
REV-0
Page 3 of 3
NOTE:
1.
FOR THE APPLICABLE SIZE NOS., DIMENSION TABLE, NOTES AND VIEW A-A, REFER GAIL
STANDARD S-05-01-021.
GAIL (INDIA) LTD

NEW DELHI
RESTRAINED LOW SUPPORT

L8A
DOCUMENT NO.
S-05-01-026
REV-0
Page 1 of 1
1.
PLACE SUPPORT UNDER PIPE BEFORE CONNECTING PIPE TO EQUIPMENT. TURN

ADJUSTING NUT UNTIL PIPE FLANGE IS ALIGNED WITH EQUIPMENT OR VALVE FLANGE.
NOTES:
1.
ALL PLATES SHALL BE CARBON STEEL WHERE DESIGN TEMPERATURE 4000C WITH h
200mm. BASE PLATE MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL.
2.
REFER NOTES 2, 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.
3.
IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (D1) LISTED IN TABLE ABOVE IS
NOT AVAILABLE, USE THE NEXT HIGHER SIZE AND / OR NEARESR HIGHER THICKNESS
AVAILABLE.
4.
HEX HEAD OF SLIDING BOLT TO BE GROUND SMOOTH.
GAIL (INDIA) LTD

NEW DELHI
ADJUSTABLE LOW SUPPORT SLIDING

L10A
DOCUMENT NO.
S-05-01-027
REV-0
Page 1 of 1
NOTES:
1.
FOR DETAILS OF U-BOLT TYPE C-4, REFER GAIL STANDARD S-05-01-021.
2.
U-BOLT MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE.
GAIL (INDIA) LTD

NEW DELHI
LOW SUPPORT SLIDING AND FIXED

SIZE 3/4 THRU 1-1/2, TYPE L15
DOCUMENT NO.
S-05-01-028
REV-0
Page 1 of 2
3.
FOR DETAIL-M, FOR CARBON STEEL (CS) PIPE, USE CS ANGLE. IN CASE OF ALLOY STEEL /
STAINLESS STEEL USE 6MM THK. PLATE MATERIAL EQUIVALENT TO THAT OF LINE PIPE.
4.
IN CASE CALCULATED H EXCEEDS THE MAXIMUM VALUE, THE PEDESTAL SHALL BE

RAISED ACCORDINGLY.
GAIL (INDIA) LTD

NEW DELHI
LOW SUPPORT SLIDING AND FIXED

SIZE 3/4 THRU 1-1/2, TYPE L15
DOCUMENT NO.
S-05-01-028
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
LOW SUPPORT STANCHION FOR

BARE AND INSULATED CS / AS / SS
PIPE, TYPE L16
DOCUMENT NO.
S-05-01-029
REV-0
Page 1 of 1
1.

NOTES:
1.
ALL PLATES SHALL BE CARBON STEEL.
2.
REFER NOTES 2, 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.
GAIL (INDIA) LTD

NEW DELHI
ADJUSTABLE LOW SUPPORT

WITH FOUR BOLTS FOR
PIPE SIZES 8 THRU 24, TYPE L17
AND L17A
DOCUMENT NO.
S-05-01-030
REV-0
Page 1 of 2
3.
AVAILABLE.
GAIL (INDIA) LTD

NEW DELHI
ADJUSTABLE LOW SUPPORT

WITH FOUR BOLTS FOR
PIPE SIZES 8 THRU 24, TYPE L17
AND L17A
DOCUMENT NO.
S-05-01-030
REV-0
Page 2 of 2
1.

NOTES:
1.
ALL PLATES SHALL BE CARBON STEEL. THE STUB PIPE MATERIAL SHALL BE
EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE OF
CARBON STEEL.
2.
REFER NOTES 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.
3.
AVAILABLE.
GAIL (INDIA) LTD

NEW DELHI
ADJUSTABLE LOW SUPPORT FOR

BARE AND INSULATED PIPE,
SIZES 2 THRU 24, TYPE L18 AND
L18A
DOCUMENT NO.
S-05-01-031
REV-0
Page 1 of 1
1.

NOTES:
1.
ALL PLATES SHALL BE CARBON STEEL. THE STUB PIPE MATERIAL SHALL BE
EQUIVALENT TO THAT OF LINE PIPE AND THE LOWER SUPPORT PIPE SHALL BE OF
CARBON STEEL.
2.
REFER NOTES 4, 5 & 6 AND VIEW A-A OF GAIL STANDARD S-05-01-021.
GAIL (INDIA) LTD

NEW DELHI
ADJUSTABLE LOW SUPPORT WITH

GUIDE AND CROSS GUIDE FOR BARE
AND INSULATED PIPE,
L19A
DOCUMENT NO.
REV-0
Page 1 of 2
S-05-01-032
3.
AVAILABLE.
GAIL (INDIA) LTD

NEW DELHI
ADJUSTABLE LOW SUPPORT WITH

GUIDE AND CROSS GUIDE FOR BARE
AND INSULATED PIPE,
L19A
DOCUMENT NO.
REV-0
Page 2 of 2
S-05-01-032
GAIL (INDIA) LTD

NEW DELHI
PIPE CLAMP FOR BARE CS / AS / SS

PIPE, SIZE THRU 24, TYPE C1
DOCUMENT NO.
S-05-01-033
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
U-BOLT FOR BARE CS PIPE,

SIZE THRU 24, TYPE C4
DOCUMENT NO.
S-05-01-034
REV-0
Page 1 of 1
NOTES:
TO BE GIVEN IN CASE SUPPORT IS WELDED TO VERTICAL
1.
REFERENCE LEVEL AND

SUPPORT.
2.
DIMENSION M LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE

STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE REST OF SUPPORT
PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF M SHALL BE INSULATION THICKNESS
+ 25MM.
FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CARBON STEEL
I.E. M=0.
GAIL (INDIA) LTD

NEW DELHI
DUMMY PIPE SUPPORT FOR BARE

PIPE, SIZE 2 THRU 24, TYPE-B39
DOCUMENT NO.
S-05-01-035
REV-0
Page 1 of 2
3.
THE FOLLOWING:
-
FOR (L-0.50) 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE

EQUIVALENT TO THAT OF LINE PIPE I.E. M= (L-0.50).
FOR (L-0.50) > 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M =

25MM + INSULATION THICKNESS OR 100MM WHICHEVER IS GREATER.
IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (d) LISTED IN ABOVE TABLE IS NOT
AVAILABLE, USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THIOCKNESS AVAILABLE.
GAIL (INDIA) LTD

NEW DELHI
DUMMY PIPE SUPPORT FOR BARE

PIPE, SIZE 2 THRU 24, TYPE-B39
DOCUMENT NO.
S-05-01-035
REV-0
Page 2 of 2
NOTES:
TO BE GIVEN IN CASE SUPPORT IS WELDED TO VERTICAL
1.
REFERENCE LEVEL AND

SUPPORT.
2.
DIMENSION M LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE

STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF LINE PIPE AND THE REST OF SUPPORT
PIPE SHALL BE CARBON STEEL. MINIMUM VALUE OF M SHALL BE INSULATION THICKNESS
+ 25MM.
FOR CARBON STEEL LINE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CARBON STEEL
I.E. M=0.
DOCUMENT NO.
REV-0
DUMMY PIPE SUPPORT FOR
GAIL (INDIA) LTD
INSULATED PIPE, SIZE 2 THRU 24,
Page 1 of 2
S-05-01-036
NEW DELHI
TYPE- B40
3.
THE FOLLOWING:
-
FOR (L-0.50) 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE

EQUIVALENT TO THAT OF LINE PIPE I.E. M= (L-0.50).
FOR (L-0.50) > 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH M =

25MM + INSULATION THICKNESS OR 100MM WHICHEVER IS GREATER.
IN CASE SIZE AND / OR SCHEDULE OF SUPPORT PIPE (d) LISTED IN ABOVE TABLE IS NOT
AVAILABLE, USE NEXT HIGHER SIZE AND / OR NEAREST HIGHER THIOCKNESS AVAILABLE.
GAIL (INDIA) LTD

NEW DELHI
DUMMY PIPE SUPPORT FOR

INSULATED PIPE, SIZE 2 THRU 24,
TYPE- B40
DOCUMENT NO.
S-05-01-036
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
PIPE SUPPORT BRACKETS, TYPE- B42
S-05-01-037
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
GUIDE SUPPORT FOR BARE PIPE,

SIZE THRU 24, TYPE- G1
DOCUMENT NO.
S-05-01-038
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI

SIZE THRU 24, TYPE- G2 AND G2A
DOCUMENT NO.
S-05-01-039
REV-0
Page 1 of 2
NOTES:
1.
LOADS ON FILLET WELDS OF GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE
AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD.
LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2.
GUIDE PLATES / ANGLES SHALL BE WELDED ON BOTH SIDES.
3.
GUIDE ANGLES SHALL BE SUITABLY TRIMMED WHENEVER THEY ARE OBSTRUCTING ADJACENT
GUIDE ANGLES.
4.
PROTECTION SHIELD SHALL BE PROVIDED ON ALL LINES 14 AND ABOVE. IT SHALL BE CUT FROM
LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT TO LINE PIPE. THICKNESS OF
PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS LESS.
GAIL (INDIA) LTD

NEW DELHI

SIZE THRU 24, TYPE- G2 AND G2A
DOCUMENT NO.
S-05-01-039
REV-0
Page 2 of 2
NOTES:
1.
LOADS ON FILLET WELDS OF CROSS GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE
AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD.
LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
GAIL (INDIA) LTD

NEW DELHI
CROSS GUIDE FOR BARE PIPE,

SIZE 2 THRU 24, TYPE- G3
DOCUMENT NO.
S-05-01-040
REV-0
Page 1 of 2
2.
FOR AS AND SS LINES, SIZES 2 THRU 12, PROTECTION SHIELD AS PER NOTE-3 IS TO BE PROVIDED.
3.
PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL
EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR
12MM, WHICHEVER IS LESS.
4.
IN CASE OF BEAM TYPE SUPPORTING STEEL, PLATES SHALL BE PROVIDED ON BOTH SIDES AS SHOWN.
HEIGHT OF THE PLATE SHALL BE BASED ON THE SIZE OF THE SUPPORTING STEEL MEMBER.
GAIL (INDIA) LTD

NEW DELHI
CROSS GUIDE FOR BARE PIPE,

DOCUMENT NO.
S-05-01-040
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
CROSS GUIDE FOR BARE PIPE ON

SLEEPER / RCC BEAM,
DOCUMENT NO.
S-05-01-041
REV-0
Page 1 of 2
NOTE:
1. LOADS ON FILLET WELDS OF GUIDES SHALL BE LIMITED TO THE VALUES TABULATED ABOVE
AGAINST VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF
WELD. LOADS MAY BE INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2. FOR AS / SS LINES OF SIZES 2 THRU 12, PROTECTION SHIELD AS PER NOTE-3 IS TO BE
PROVIDED.
EQUIVALENT TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE
OR 12MM, WHICHEVER IS LESS.
4. FOR SUPPORTING DETAILS OF PIPE SIZES 2 THRU 6, REFER GAIL STANDARD S-05-01-040.
GAIL (INDIA) LTD

NEW DELHI
CROSS GUIDE FOR BARE PIPE ON

SLEEPER / RCC BEAM,
DOCUMENT NO.
S-05-01-041
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
ANCHOR FOR BARE PIPE ON

SLEEPER / RCC BEAM,
DOCUMENT NO.
S-05-01-042
REV-0
Page 1 of 2
NOTES:
1.
LOADS ON FILLET WELDS OF ANCHORS SHALL BE LIMITED TO THE VALUES TABULATED ABOVE AGAINST
VARIOUS TEMPERATURES FOR RESPECTIVE WELD SIZE, FOR RUNNING LENGTH OF WELD. LOADS MAY BE
INTERPOLATED FOR INTERMEDIATE TEMPERATURES.
2.
FOR AS / SS LINES OF SIZES 2 THRU 12, PROTECTION SHIELD AS PER NOTE-3 IS TO BE PROVIDED.
3.
PROTECTION SHIELD SHALL BE CUT FROM LINE PIPE OR ROLLED FROM PLATE OF MATERIAL EQUIVALENT
TO LINE PIPE. THICKNESS OF PROTECTION SHIELD SHALL BE SAME AS LINE PIPE OR 12MM, WHICHEVER IS
LESS.
4.
FOR SUPPORTING DETAILS OF PIPE SIZES 2 THRU 6 , REFER GAIL STANDARD S-05-01-040. CROSS GUIDE
GAP SHALL BE MADE ZERO AND RESTRAINT FACE SHALL BE WELDED TO SLEEPER INSERT PLATES ON
EITHER SIDE.
GAIL (INDIA) LTD

NEW DELHI
ANCHOR FOR BARE PIPE ON

SLEEPER / RCC BEAM,
DOCUMENT NO.
S-05-01-042
REV-0
Page 2 of 2
GAIL (INDIA) LTD

NEW DELHI
SUPPORTING ARRANGEMENT FOR

ANGLE AND RELIEF VALVES, TYPE
SP2
DOCUMENT NO.
S-05-01-043
REV-0
Page 1 of 1
GAIL (INDIA) LTD

NEW DELHI
TYPICAL ANTI VIBRATION SUPPORT

FOR CONTROL VALVE MANIFOLD,
TYPE SP3
DOCUMENT NO.
S-05-01-044
REV-0
Page 1 of 1
Valve Manufacturer
Actuator Manufacturer
Valve Tag No.
Purchasers spec.:
S 04 02 - 007
Design standard:
API 6D
SIZE, mm (IN) NB:
Ends:
BOTH ENDS BW
PER ASME B 16.25
VALVE DESIGN CONDITIONS:
Corrosion Allowance:
1.5 mm
Service
R-LNG
Design factor:
0.5
-------------
AS
ANSI Rating:
Piping class:
VALVE BORE:
Face
finish
flanges:
Temperature, 0c:
Installation:
Valve Operating
time, Sec
of
600#
D1A
FULL / REDUCED BORE
NOT APPLICABLE
-28 TO 65
BURIED
60
CONNECTING PIPE DETAILS:

Diameter (NB), mm
Wall Thickness, mm
VALVE OPERATOR REQUIREMENT
Type of Operator
GAS POWERED
ACTUATOR
Operator Spec. No.:
S 04 02 - 012
Operator Data Sheet:
STEM EXTENSION REQUIREMENT

Stem Extension
REQUIRED
Length of Stem
extension, m
VALVE MATERIAL SPECIFICATION:

PART DESCRIPTION
SPECIFIED MATERIAL
Body
ASTM A 216 Gr. WCB/ ASTM A 234
Gr. WPB (REFER NOTE-1)
Ball
(ASTM A 216 Gr. WCB/ ASTM A
234 Gr. WPB) + 0.003 ENP
Body Seat Rings
(AISI 4140 + 0.003 ENP) / AISI 410
Seat Seal (Secondary)
VITON
Stem
(AISI 4140 + 0.003 ENP) / AISI 410
Stem seal
PTFE / VITON
Stud, Bolts
ASTM A 193 Gr. B7/ Gr. B7M
Nuts
ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7
2.5 (APPROX.)
MATERIAL OFFERED
Note:
1. Material for body shall have guaranteed minimum yield strength of 46,700 psi. In
case the same can not be guaranteed, Valves shall be supplied with PUP pieces of
500mm length, integrally welded to the valve, whose strength shall be equivalent
to connecting pipe specifications.
2. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at
pipe end) shall be 5.0mm.
3. Compressed asbestos filler (CAF) shall not be used for body sealing/ gasket
materials.
4. All valves shall be suitable for location operation & remote actuated operation as
per specification No. S-04-02-012.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DATA SHEET FOR BALL VALVES
0001-01-04-04-BV-001
REV-0
Page 1 of 1
Valve Manufacturer
Valve Tag No.
Purchasers spec.:
S 04 02 - 007
Design standard:
API 6D
SIZE, mm (IN) NB:
Ends:
BOTH ENDS BW
PER ASME B 16.25
1.5 mm
Service
R-LNG
Design factor:
0.5
-------------
AS
ANSI Rating:
Piping class:
VALVE BORE:
Face
finish
flanges:
Temperature, 0c:
Installation:
Valve Operating
time, Sec
of
600#
D1A
FULL / REDUCED BORE
NOT APPLICABLE
-28 TO 65
ABOVE GROUND
60

Diameter (NB), mm
Wall Thickness, mm
Type of Operator
GAS POWERED
ACTUATOR
Operator Spec. No.:
S 04 02 - 012

Stem Extension
NOT APPLICABLE
Length of Stem
extension, m

PART DESCRIPTION
SPECIFIED MATERIAL
Body
Ball
234 Gr. WPB) + 0.003 ENP
Body Seat Rings
(AISI 4140 + 0.003 ENP) / AISI 410
VITON
Stem
(AISI 4140 + 0.003 ENP) / AISI 410
Stem seal
PTFE / VITON
Stud, Bolts
Nuts
ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7
-----
MATERIAL OFFERED
Note:
minimum ID at pipe end) shall be 5.0mm.
materials.
4. All valves shall be suitable for location operation & remote actuated operation as
per specification No. S-04-02-012.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DATA SHEET FOR BALL VALVES
0001-01-04-04-BV-002
REV-0
Page 1 of 1
Valve Manufacturer
Valve Tag No.
Purchasers spec.:
S 04 02 - 007
Design standard:
API 6D
SIZE, mm (IN) NB:
Ends:
BOTH ENDS BW
PER ASME B 16.25
1.5 mm
Service
R-LNG
Design factor:
0.5
-------------
AS
ANSI Rating:
Piping class:
VALVE BORE:
Face
finish
flanges:
Temperature, 0c:
Installation:
Valve Operating
time, Sec
of
600#
D1A
FULL / REDUCED BORE
NOT APPLICABLE
-28 TO 65
BURIED
GROUND
60
ABOVE

Diameter (NB), mm
Wall Thickness, mm
Type of Operator
GEAR OPERATED
Operator Spec. No.:

Stem Extension
NOT APPLICABLE
----Length of Stem
extension, m

PART DESCRIPTION
SPECIFIED MATERIAL
Body
Ball
234 Gr. WPB) + 0.003 ENP
Body Seat Rings
(AISI 4140 + 0.003 ENP) / AISI 410
VITON
Stem
(AISI 4140 + 0.003 ENP) / AISI 410
Stem seal
PTFE / VITON
Stud, Bolts
Nuts
ASTM A 194 Gr. 2H/ Gr. 4/ Gr. 7
MATERIAL OFFERED
Note:
minimum ID at pipe end) shall be 5.0mm.
materials.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DATA SHEET FOR BALL VALVE
0001-01-04-04-BV-003
REV-0
Page 1 of 1
Valve Manufacturer
Valve Tag No.
Purchasers spec.:
S 04 02 008
Design standard:
API 6D
SIZE, mm (IN) NB:
Ends:
BOTH ENDS BW
PER ASME B 16.25
1.5 mm
Service
R-LNG
Design factor:
0.5
------------ANSI Rating:
Piping class:
AS
Face
finish
flanges:
Temperature, 0c:
Installation:
600#
D1A
of
NOT APPLICABLE
-28 TO 65
ABOVE GROUND

Diameter (NB), mm
Wall Thickness, mm
7.9
Grade
API 5L Gr. X60
Type of Operator
Manual (Note-1)
Operator Spec. No.:
-

Stem Extension
Not Required
Length of Stem
extension, m

PART DESCRIPTION
SPECIFIED MATERIAL
Body
Gr. WPB
Plug
234 Gr. WPB) + 0.003 ENP
Cover
Gr. WPB
Stem
(AISI 4140 + 0.003 ENP) / AISI 410
Stem seal
PTFE / GRAPHITE / VITON
Stud, Bolts
ASTM A 193 Gr. B7
Nuts
ASTM A 194 Gr. 2H
MATERIAL OFFERED
Note:
Requirement of Manual operator (Wrench / Hand Wheel / Gear operator) shall be
as per Specification - S0402008.
2. Separate wrench shall be provided with each wrench operated valve.
3. Data Sheets shall be read in conjunction with Valve specifications - S0402008.
1.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DATA SHEET FOR PLUG VALVES
0001-01-04-04-PV-001
REV-0
Page 1 of 1
Valve Manufacturer
Valve Tag No.
Purchasers spec.:
S 04 02 008
Design standard:
API 6D
SIZE, mm (IN) NB:
Ends:
BOTH ENDS BW
PER ASME B 16.25
1.5 mm
Service
R-LNG
Design factor:
0.5
------------ANSI Rating:
Piping class:
AS
Face
finish
flanges:
Temperature, 0c:
Installation:
600#
D1A
of
NOT APPLICABLE
-28 TO 65
BURIED

Diameter (NB), mm
Wall Thickness, mm
7.9
Grade
API 5L Gr. X60
Type of Operator
Manual (Note-1)
Operator Spec. No.:
-

Stem Extension
Required
2.5 M (Approx.)
Length of Stem
extension, m

PART DESCRIPTION
SPECIFIED MATERIAL
Body
Gr. WPB
Plug
234 Gr. WPB) + 0.003 ENP
Cover
Gr. WPB
Stem
(AISI 4140 + 0.003 ENP) / AISI 410
Stem seal
PTFE / GRAPHITE / VITON
Stud, Bolts
ASTM A 193 Gr. B7
Nuts
ASTM A 194 Gr. 2H
MATERIAL OFFERED
Note:
Requirement of Manual operator (Wrench / Hand Wheel / Gear operator) shall be
as per Specification - S0402008.
2. Separate wrench shall be provided with each wrench operated valve.
3. Data Sheets shall be read in conjunction with Valve specifications - S0402008.
1.
GAIL (INDIA) LTD

NEW DELHI
DOCUMENT NO.
DATA SHEET FOR PLUG VALVES
0001-01-04-04-PV-002
REV-0
Page 1 of 1
DATA SHEETS GATE VALVE BELOW 2

SPUR LINES OF CHAINSA - JHAJJAR
DATA SHEET GATE VALVE BELOW 2
GAIL (INDIA) LTD

NEW DELHI
DATA SHEET
0001-01-05-04-GV-001
REV-0
Page 1 of 3
Client
Gail (India) Ltd
Client
Gail (India)Ltd
Project
Std. Specification
Location :
New Delhi
Tag No:
GATE VALVE SPECIFICATION

TAG NO. :
RATING :
SIZE RANGE : 0.25" TO 1.5"
STANDARD : API-602
ENDS : SW 3000 TO B-16.11
DESCRIPTION
CONSTRUCTION
BODY
FORGED
ASTM A 105
BONNET
BOLTED
ASTM A 105
STEM
RISING
13% CR.STEEL (NO CASTING)
WEDGE DISC
SOLID
STELLITED
BODY SEAT RING
RENEWABLE
STELLITED
STEM PACKING
RENEWABLE WITH
VALVE OPEN ON
STREAM
GRAPHITED ASBESTOS WITH

SACRIFICIAL CORR. INHIB.& INCONEL
WIRE REINFORCEMENT
HAND WHEEL
NON RISING
MALLEABLE IRON/CAST ST/FAB.ST/DUCT.

IRON
MATERIAL
BONNET BOLTS
ASTM A193 GR B7
BONNET NUTS
ASTM A194 GR 2H
BONNET GASKET
SP WND SS316 - CA F1LLER
SPECIAL SERVICE
CONDITIONS
MAX TEMP. 427 DEG. C.

INTEGRAL
OTHERS
O.S & Y.
HYDROSTATIC TEST
PRESSURE
BODY : 2975 PSIG.
TEST PRESSURE
WITH AIR
80 PSIG
of
MANUF'S OFFER
PIPING CLASS : A10A, A11A, A13A, A1A, A20A,

A32A, A33A, A3A, A6A, A9A, B13A, B1A, B32A, B6A,
B9A, D1A
BACK SEAT &

SHOULDER
Sheet No.
STANDARD:
MFGRS CAT/FIG:
RATING: ENDS:
CONSTRUCTION
MATERIAL
SEAT : 2175 PSIG
NOTES
1
2
3
4
5
THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES.
BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN
THE SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH SPEC BIDDER SHALL INDICATE
"AGREED".
NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED.
TESTING SHALL BE AS PER API 598
GAIL (INDIA) LTD

NEW DELHI
DATA SHEET
0001-01-05-04-GV-001
REV-0
Page 2 of 3
Project
Location :
Std. Specification
New Delhi
Tag No:
GATE VALVE SPECIFICATION

TAG NO.
RATING : 800
SIZE RANGE : 0.5" TO 1.5"
DESCRIPTION
CONSTRUCTION
BODY
FORGED
ASTM A 350 GR.LF2
BONNET
BOLTED
ASTM A 350 GR.LF2
STEM
RISING
SS 304/SS316 (NO CASTING)
WEDGE DISC
SOLID
STELLITED
BODY SEAT RING
RENEWABLE
STELLITED
STEM PACKING
RENEWABLE WITH
VALVE OPEN ON
STREAM
ASBESTOS IMPREGNATED WITH PTFE
HAND WHEEL
NON RISING
MALLEABLE IRON/CAST ST/FAB.ST/DUCT.

IRON
MATERIAL
BONNET BOLTS
ASTM A320 GR L7
BONNET NUTS
ASTM A194 GR 4/GR 7
BONNET GASKET
SP WND SS316 - CA FILLER

LT
BACK SEAT &

SHOULDER
INTEGRAL
OTHERS
O.S & Y.
HYDROSTATIC TEST
PRESSURE
BODY : 2975 PSIG.
TEST PRESSURE
WITH AIR
80 PSIG
of
MANUF'S OFFER
PIPING CLASS : A4A, B4A, D4A

STANDARD : API-602
ENDS : SW 3000 TO B-16.11
SPECIAL SERVICE
CONDITIONS
Sheet No.
STANDARD:
MFGRS CAT/FIG:
RATING:
ENDS:
CONSTRUCTION
MATERIAL
UPTO -45 DEG. C.
SEAT : 2175 PSIG
NOTES
1
2
3
4
5
6
THIS VALVE SPEC SHEET SHALL BE READ IN CONJUNCTION WITH TECHNICAL NOTES FOR VALVES.
BIDDER SHALL CLEARLY WRITE ALL/ ANY DEVIATION AGAINST EACH PART/ MATERIAL OF VALVE IN
THE SPACE PROVIDED FOR. WHEREVER BIDDER AGREES WITH SPEC BIDDER SHALL INDICATE
"AGREED".
NO CUTTING/ OVERWRITING BY BIDDER ON SPEC IS ALLOWED.
TESTING SHALL BE AS PER API 598 & BS-6364.
VALVES SHALL BE PROVIDED WITH EXTENDED BONNET AS PER BS 6364 (NON COLD BOX
APPLICATION).
VALVES TO COMPLY WITH DESIGN REQUIREMENTS OF BS-6364 ALSO.
GAIL (INDIA) LTD

NEW DELHI
DATA SHEET
0001-01-05-04-GV-001
REV-0
Page 3 of 3
ITEM
REFERENCE SPECIFICATION
PIPE LINE FLOW TEE (BARRED TEE)

SPEC. NO.: S 04 02 - 016
INSTALLATION CONDITIONS:
LOCATION
SULTANPUR PIG LAUNCHER STATION, NEEMRANA
PIG RECEIVER STATION
INSTALLATION
ABOVE GROUND
DESIGN CONDITIONS:
BARRED TEE SIZE (NB, INCHES)
DESIGN CODE
DESIGN FACTOR
CORROSION ALLOWANCE
DESIGN PRESSURE
DESIGN TEMPERATURE
IMPACT TEST TEMPERATURE
TRANSPORTED GAS
SOUR SERVICE
OF FIELD WELDS
RADIOGRAPHY INSPECTION
PAINTING
MATERIALS:
TEE
GUIDE BARS
NO. OF BARS
TEST RING (1 NO.)
18 X 18 X 18
ASME B 31.8
0.5
NIL
99.93 KG/CM2 (G)
(-) 28 TO 650C
(-) 280C
NATURAL GAS
NO
NO
IF WALL THICKNESS OF TEE IS GREATER THAN
20MM, RI SHALL BE REPLACED WITH UT
AS PER CLAUSE 6.0 OF SPECIFICATION
NO. S 04 02 - 016
MSS SP-75, Gr. WPHY-70

MANUFACTURER TO SPECIFY
9
18 X 500MM X 9.3 MM
CONNECTING PIPE DETAILS

HEADER PIPE DETAILS
BRANCH PIPE DETAILS
O.D X W.T (mm)
SPEC.
O.D X W.T (mm)
SPEC.
457 X 9.3
API 5L Gr. 70
457 X 9.3
API 5L Gr. 70
GAIL (INDIA) LTD

NEW DELHI
DATA SHEET FOR BARRED TEE

SIZE 18 X 18 X 18
DOCUMENT NO.
0001-01-04-04-FLT-001
REV-0
Page 1 of 1
ITEM

SPEC. NO.: S 04 02 - 016
LOCATION
DHARUHERA TOP, BHIWADI-CHOPANKI TOP,
KHUSHKHERA TOP
INSTALLATION
UNDER GROUND
DESIGN CONDITIONS:
DESIGN CODE
DESIGN FACTOR
CORROSION ALLOWANCE
DESIGN PRESSURE
DESIGN TEMPERATURE
TRANSPORTED GAS
SOUR SERVICE
OF FIELD WELDS
PAINTING
MATERIALS:
TEE
GUIDE BARS
NO. OF BARS
TEST RING (1 NO.)
18 X 18 X 12
ASME B 31.8
0.5
NIL
99.93 KG/CM2 (G)
(-) 28 TO 650C
(-) 280C
NATURAL GAS
NO
NO
NO. S 04 02 - 016

3
12 X 500MM X 7.9 MM

HEADER PIPE DETAILS
BRANCH PIPE DETAILS
O.D X W.T (mm)
SPEC.
O.D X W.T (mm)
SPEC.
457 X 9.3
API 5L Gr. 70
323.9 X 7.9
API 5L Gr. 60
GAIL (INDIA) LTD

NEW DELHI

SIZE 18 X 18 X 12
DOCUMENT NO.
0001-01-04-04-FLT-002
REV-0
Page 1 of 1
ITEM

SPEC. NO.: S 04 02 - 016
LOCATION
TOP IN U/S OF SV-1 & SV-3 IN SULTANPURNEEMRANA SPUR LINE
INSTALLATION
UNDER GROUND
DESIGN CONDITIONS:
DESIGN CODE
DESIGN FACTOR
CORROSION ALLOWANCE
DESIGN PRESSURE
DESIGN TEMPERATURE
TRANSPORTED GAS
SOUR SERVICE
OF FIELD WELDS
PAINTING
MATERIALS:
TEE
GUIDE BARS
NO. OF BARS
TEST RING (1 NO.)
18 X 18 X 8
ASME B 31.8
0.5
NIL
99.93 KG/CM2 (G)
(-) 28 TO 650C
(-) 280C
NATURAL GAS
NO
NO
NO. S 04 02 - 016

3
8 X 500MM X 6.4 MM

HEADER PIPE DETAILS
BRANCH PIPE DETAILS
O.D X W.T (mm)
SPEC.
O.D X W.T (mm)
SPEC.
457 X 9.3
API 5L Gr. 70
219.1 X 6.4
API 5L Gr. 56
GAIL (INDIA) LTD

NEW DELHI

SIZE 18 X 18 X 8
DOCUMENT NO.
0001-01-04-04-FLT-003
REV-0
Page 1 of 1
PIG SIGNALLER TAG NO.
ON EQUIPMENT
DATA SHEET NO.
PIG SIGNALLER MANUFACTURER

PURCHASER'S SPECIFICATIONS
PIG SINGALLER MODEL
QUANTITY
12-PL-01, 13-PR-01
0001-01-04-04-PSG-001
*
S 04 02 - 018
*
4
DESIGN CONDITIONS
DESIGN PRESSURE (KG/CM)
DESIGN TEMPERATURE (C)
DESIGN CODE
CORROSION ALLOWANCE (MM)
ANSI RATING (#)
DESIGN FACTOR
SERVICE
END CONNECTION
INSTALLATION
ELECTRICAL AREA CLASSIFICATION
99.93
-28 TO 65
ASME B31.8 & OISD 226
1.5
600
0.5
NATURAL GAS
BE
ABOVE GROUND
IEC - ZONE-1, GAS GROUP-IIA & IB,
TEMP. CLASS - T3
PIG SIGNALLER MATERIAL SPECIFICATION

BODY
INTERNALS
ASTM A105 (CHARPY)

SS-316
MICRO SWITCH DETAILS

RATING
ENCLOSURE
CABLE CONNECTION
GAIL (INDIA) LTD

NEW DELHI
POTENTIAL FREE CONTACT OF RATING

24V DC, 2A, SPDT
WEATHER PROOF TO IP55 & FLAME PROOF EXD.
ENCLOSURE CERTIFIED FOR AREA
CLASSIFICATION
1/2" NPTF
DOCUMENT NO.
DATA SHEET FOR PIG SIGNALER
0001-01-04-04-PSG-001
REV-0
Page 1 of 1
DATA SHEET FOR GAS POWERED ACTUATOR

Specification for Gas Powered Actuator
____________________
S-04-02-012
Vendor to take the following data for sizing the actuator and furnish the filled in torque
figures in Table-1 after sizing the actuator.
1.
Tag Nos.
2.
Service
3.
Actuator Shut off Pressure
4.
Actuator Valve Description

Item No.
1
2
3
4
Size, NB mm (in)
18
12
10
8
Corrosion Allowance
5.
NATURAL GAS
92 kg/cm2 (g)
Bore Size
Full Bore &
Reduced Bore
ANSI Rating
600#
600#
600#
600#
1.5 mm
Process Condition:
Power Gas
Gas Temperature
Line gas Pressure
Molecular Weight
Cp/Cv
Compressibility Factor
:
:
:
:
:
:
Natural Gas
-29 to 650C
92 KG/CM2 (MAX.)
17.4 17.64
1.50 1.60/ 1.65 1.75
0.84-0.86 / 0.78 0.81 /
0.83 0.87
6.
Actuator Type
As per Specification
7.
Power Gas feed from Connection

from Mainline
3/4" NPT
8.
Actuator Remote Operation

(for open/close)
Required
9.
Valve Position Limit Switch
Required (SPDT contact for open

and SPDT contact for close
positions separately)
GAIL (INDIA) LTD

NEW DELHI
DATA SHEET FOR GAS POWERED

VALVE ACTUATOR
DOCUMENT NO.
0001-01-04-04-GVA-001
REV-0
Page 1 of 4
10.
Local/ Remote Selector Switch

and its Status contact
Required
(shall be wired up to junction box
as per circuit diagram)
11.
Pneumatic Limit Valves and

solenoid, pilot valves to shut off
gas supply to actuator when valve
reaches one of its end positions
Required
12.
Self Retaining System for retaining

momentary open and close signals
in the control circuit
Required
13.
Electrical Conduit connection

(Cable entry to junction box for
Purchasers cable)
1" NPT
14.
Operating Voltage
:
24 V DC 15 %
Limit Switches
L/R switch (status)
2 Amp at 24 V DC
16.
Pad Lock with L/R Switch
Required
17.
Enclosure for
a)
b)
15.
Solenoid Valves
Relays
Contact Rating
a)
b)
a)
Actuator
Certified Weather Proof as per

IP55
b)
Electrical Items like Limit

Switches, Solenoid valves,
Junction Boxes, Relays,
Cable Glands
Certified Weather Proof as per

IP55 and Flame proof certified
suitable for IEC Zone-1, Gas
group IIA &IIB, Temp. Class T3
18.
Area Classification
IEC Zone-I, Gas Group II A & IIB,

Temp. Class T3
19.
Material of Construction for all

tubing, valves, piping and fittings
SS316
20.
Accessories Required
Required as per Specification
21.
Manual/Hydraulic Override
Required as per Specification
GAIL (INDIA) LTD

NEW DELHI

VALVE ACTUATOR
DOCUMENT NO.
0001-01-04-04-GVA-001
REV-0
Page 2 of 4
22.
Maximum time required to open/close

the valve
As per Data sheets
Note:
Complete actuator including control panel/ systems shall be manufactured and supplied
by actuator manufacturer only. All circuit diagram / documents/ drawings pertaining to
actuator shall be furnished by actuator manufacturer. All inspection and testing shall be
carried out at actuator manufacturers shop as per clause 6.1 of Spec. No. S-04-02-012.
GAIL (INDIA) LTD

NEW DELHI

VALVE ACTUATOR
DOCUMENT NO.
0001-01-04-04-GVA-001
REV-0
Page 3 of 4
TABLE - 1
DATA FROM BALL VALVE VENDOR

ITEM
NO.
TAG
NO.
BREAK
TORQUE
(NM)
RUNNING
TORQUE
(NM)
MAX.
ALLOWABLE
STEM
TORQUE
(NM)
BALL VALVE TORQUE

FIGURES WITH A
SAFETY FACTOR 1.25
ACTUATOR
GENERATED TORQUE
AT 10 KG/CM2 (G)
REGULATED
PRESSURE (NOTE 1)
BREAK
TORQUE
(NM)
BREAK
TORQUE
(NM)
RUNNING
TORQUE
(NM)
MODEL
SELECTED
RUNNING
TORQUE
(NM)
Notes:
1. These figures shall be used as basis for testing the actuator performance during
factory testing. The actuator acceptance would be carried out after verifying
successful testing complete of ball valves with actuator assembly.
2. All torque figures must be in Nm.
GAIL (INDIA) LTD

NEW DELHI

VALVE ACTUATOR
DOCUMENT NO.
0001-01-04-04-GVA-001
REV-0
Page 4 of 4
A = OVERALL LENGTH OF IJ TO BE CONFIRMED BY MANUFACTURER.

1. INSULATING JOINTS MFR.
2. PURCHASER'S SPECIFICATION NO.
3. RATING
4. DESIGN PRESSURE
5. DESIGN TEMPERATURE
6. SERVICE
7. CORROSION ALLOWANCE
8. SIZE NB (INCHES)
9. END CONNECTION
10. DESIGN CODE
11. DESIGN FACTOR
12.
13.
14.
15.
:
:
:
:
:
:
:
:
:
:
:
S 04 02 - 019
600#
99.93 KG/CM2 (G)
-29 TO 65C
Natural Gas
1.5 MM
18 / 12 / 10 / 8
BUTT-WELD AT BOTH ENDS
ASME SECTION-VIII DIV-I
0.4 (FOR CLASS-4 LOCATION)
0.5 (FOR ALL OTHER AREAS)
HYDROSTATIC TEST PRESSURE
:
138 KG/CM2 (G)
CHARPY TEST
:
REQUIRED AS PER SPEC.
HARDNESS TEST
:
REQUIRED AS PER SPEC.
MATERIALS SPECIFICATION (EQUIVALENT OR SUPERIOR)
A) BODY
B) PUPS
C) INSULATING MATERIAL:
16. CONNECTING PIPE SPECIFICATION :
SIZE, NB, MM (INCHES)
WALL THICKNESS, MM
GRADE
17. SPECIAL REQUIREMENTS
GAIL (INDIA) LTD

NEW DELHI
:
:
:
:
ASTM A-694, GRADE AS PER

CONNECTING PIPE GRADE
API 5L (GR. &THK. TO SUIT CONNECTING
PIPE)
AS PER MANUFACTURER'S STANDARD
18" / 12 / 10 / 8
AS PER AREA CLASSIFICATION
API 5L Gr. X-70 (18)
API 5L Gr. X-60 (12 & 10)
API 5L Gr. X-56 (8)
INSULATION JOINT SHALL BE
SUITABLE FOR ABOVE GROUND
INSTALLATION
DATA SHEET FOR INSULATING

JOINTS
DOCUMENT NO.
0001-01-04-04-IJ-001
REV-0
Page 1 of 1
VENDOR LIST
The materials required to be supplied by the contractor under this contract shall be
procured only from GAIL approved vendors. However, current validity and range of
approval as per GAIL enlistment letter, workload, stability and solvency need to be
verified by the contractor before placement of order. Approved list of vendors for some
of the items are mentioned below or elsewhere in the Bidding document. Where the
makes of materials are not indicated in the bidding document, contractor shall furnish
the details of makes and shall obtain prior approval of Engineer in charge of
vendors/sub-vendors before placing orders.
1)
Fasteners
-
2)
Fittings Block forged Carbon Steel

-
3)
Eby Fasteners, India

Leader Valves Ltd, India
M.S. Fittings Mfg. Co Pvt Ltd, India
R.N. Gupta & Co. Ltd, India
Fittings from Seamless Pipe Carbon Steel

-
4)
AEP Company, India

Boltmaster India Pvt Ltd, India
Deepak Fasteners Limited, India
Fasteners & Allied Products Pvt Ltd, India
Hardwin Fasteners Pvt Ltd, India
J.J. Industries, India
Multi Fasteners Pvt Ltd, India
Nexo Industries, India
Pacific Forging & Fasteners Pvt Ltd, India
Pioneer Nuts & Bolts Pvt Ltd, India
Precision Auto Engineers, India
President Engineering Works, India
Sandeep Engineering Works, India
Syndicate Engineering Industries, India
Eby Industries, India

Gujarat Infrapipes Pvt Ltd, India
M.S. Fittings Mfg. Co Pvt Ltd, India
Teekay Tubes Pvt Ltd
Flanges - Forged Carbon Steel

-
CD Engineering Co., India

CD Industries (Ghaziabad), India
Chaudhry Hammer Works Ltd, India
Echjay Industries Pvt Ltd, (Rajkot), India
VENDOR LIST - PIPING
Page 1 of 4
5)
Flow Tee (Barred TEE)

-
6)
Jindal Saw Ltd. (Kosi Works), India

PSL Limited (Gandhidham Mfrg), India
Quick Opening End Closure

-
10)
IGP Engineers Pvt. Ltd., India

Nouva Giungas SRL, Italy
Zunt Italiana SRL., Italy
Long Radius Bends

-
9)
IGP Engineers Pvt. Ltd., India

Madras Industrial Products, India
Starflex Sealing India Pvt Ltd, India
Insulating Joints
-
8)
Multitex Filtration Engineers Ltd., India

Pipeline Engineering, UK
Technoforge SPA, Italy
Gaskets Spiral Wound

-
7)
Golden Iron & Steel Works, India

J.K. Forgings, India
JAV Forgings (P) Ltd, India
Kunj Forgings Pvt Ltd, India
Metal Forgings Pvt Ltd, India
Pradeep Metal Limited, India
Punjab Steel Works, India (The)
R.N. Gupta & Co. Ltd, India
R.P. Engineering Pvt Ltd, India
Shri Ganesh Forgings Ltd., India
Uma Shankar Khandelwal & Co., India
Forain S.R.L.
GD Engineering, India
Perry Equipment Corporation, India
Siirtec Nigi SPA
TD Williamson Inc., USA
Scraper Trap, Pig Signaller

-
Cardew Ltd., Alexeander

Forain S.R.L.
GD Engineering, India
Multitex Filtration Engineers Ltd., India
Page 2 of 4
11)
Pipe Carbon Steel (Seamless) to ASTM STDS.

-
12)
Larsen & Toubro Ltd, India
Ball Valves, Pipe Line (API 6D)

-
14)
BHEL (Trichy), India

Heavy Metals & Tubes Ltd (Mehsana), India
Indian Seamless Metal Tubes Ltd, Ahmednagar, India
Indian Seamless Metal Tubes Ltd, Baramati, India
Jindal Saw Ltd (Nashik Works), India
Mahalaxmi Seamless Ltd, India
Maharashtra Seamless Ltd, India
Sainest Tubes Pvt Ltd, India
Wuxi Erquan Special Steel Tube Co. Ltd.
Pressure Balanced Plug Valve (NFS)

-
13)
Siirtec Nigi SPA
Tectubi S.R.L.
Cooper Cameron Valv Italy SRL-FRM, Italy

Franz Schuck GmbH (Formerly Borsig)
ITAG
Kitamura Valve Manufacturing Co Ltd
Larsen & toubro Ltd, India
Microfinish Valves Ltd, India
MSA A.S.
OMS Saleri
PCC Ball Valves SRL
Perar SPA (Enq. to T.R.P. SRL)
Petrol Valves SRL
Pibiviesse SPA
Tormene Gas Technology SPA
Virgo Engineers Ltd, India
Weir Valves & Controls UK Ltd
Gate Valve, Forged Carbon Steel

-
Associated Toolings India Pvt Ltd, India

BDK Engineering Industries Ltd, India
BHEL (Trichy), India
Econo Valves Pvt Ltd, India
KSB Pumps Ltd (Coimbattore), India
Larsen & toubro Ltd, India
Leader Valves Ltd, India
Niton Valve Industries Private Ltd, India
Oswal Industries Ltd, India
Panchvati Valves & Flanges Pvt Ltd, India
Page 3 of 4
15)
Pressure Balanced Plug Valve (NFS) - FCS

-
16)
Larsen & Toubro Ltd, India
Pipe - Carbon Steel to Indian Standards

-
17)
Petrochemical Engineering Enterprises, India

Steel Strong Valves India Pvt Ltd, India
Advance Steel Tube Ltd., India

Asian Mills Pvt Ltd, India
BMW Industries Ltd(Bansal Mech Works) , India
Goodluck Steel Tubes Ltd, India
Indus Tube Limited, India
Jindal Pipes Ltd, India
Jindal Saw Ltd (Kosi Works) , India
Lalit Profiles & Steel Ind Ltd. , India
Lloyd Metals & Engineers Ltd. , India
Maharashtra Seamless Ltd, India
Man Industries Ltd, India
Mukat Pipes Ltd.,
Mukat Tanks & Vessels Ltd., India
North Eastern Tubes Ltd.
Pratibha Pipes & Strl Pvt Ltd
PSL Limited (Nani Chirai)
PSL Limited (Chennai)
Ratnamani Metals & Tubes Ltd
Sri Sarbati Steel Tubes Ltd
Steel Authority of India Ltd
Surindra Engineering Co Ltd (Rajpura), India
Surindra Engineering Co Ltd (Mumbai), India
Surya Roshni Ltd, India
Swastik Pipes Ltd,, India
The Tata Iron & Steel Co Ltd, India
Welspun Gujarat Stahl Rohren Ltd, India
Air Conditioning System package Unit

-
Batliboi & Co Ltd, India

Blue Star Ltd, India
Emerson Network Power (I) Pvt Ltd, India
Eta Engineering Pvt Ltd., India
Voltas Ltd. , India
Page 4 of 4

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VOLUME II

SPUR LINES OF CHAINSA JHAJJAR PIPE LINE

Engineering Design Basis

STANDARD SPECIFICATION PIPELINES

Specification for flanges &

Spec. for Issue and

STANDARD SPECIFICATION PIPING

Existing Under Ground Pipe

STANDARD DRAWING PIPING

Restrained Low support for bare

LAYOUT DRAWING & PORTACABIN PLAN

ENGINEERING DESIGN BASIS

GAIL (INDIA) LTD

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

DESIGN CODES AND STANDARDS

PIPELINE AND ASSOCIATED FACILITIES DESIGN

OTHER TECHNICAL REQUIREMENTS

LIST OF CODES AND STANDARDS

GAIL (INDIA) LTD

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

Tap-off point at Chainage 12 X 9

Tap-off point at Chainage 10 X 11

These pipelines are to cater the natural gas requirement of consumers at

DESIGN CODES AND STANDARDS

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

Inspection of Cross Country Pipelines-Onshore

Chemical Plant & Petroleum Refinery Piping

API Std. 1102

Steel Pipeline Crossing Railways & Highways

API Std. 1104

Standard for Welding Pipelines and Related Facilities

Petroleum & natural gas industries Pipeline transportation

In addition to above, codes and standards listed in Annexure-A of this document

SULTANPUR NEEMRANA LINE

4.1.1 Despatch cum Receipt Station at Sultanpur and Neemrana

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

4.1.4 SV-2 , TOP and CGS at Khushkhera

HAYATPUR MANESAR LINE

4.2.1 TOP Hayatpur for Manesar Line

HAYATPUR GURGAON LINE

4.3.1 PRS at Hayatpur

GAIL (INDIA) LTD

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

SALIENT FEATURES OF RESPECTIVE PIPELINE ROUTE

GAIL (INDIA) LTD

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

PIPELINE AND ASSOCIATED FACILITIES DESIGN

Stress analysis at crossing of major rivers, rail and highway etc.

Crossing analysis of rivers by HDD if applicable.

GAIL (INDIA) LTD

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved

River / Stream Crossings

River / Stream Crossings

7.3.1 Station piping to be provided at terminals, intermediate stations, SV stations shall be

7.4.1 Line pipe for main line

ENGINEERING DESIGN BASIS

Copyright GAIL All rights reserved