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VOLUME – II

PIPELINE ENGINEERING

SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE


(PHASE – II)

0 20.04.2009

PIPELINE ENGINEERING

REV. DATE
INDEX
Volume – II

PIPELINE ENGINEERING

(BIDDING DOCUMENT NO. – 8000001107)

S. TITLE REV. SPEC. No. of


NO. Pages
JOB SPECIFICATION

1 Engineering Design Basis 0 0001-01-04-03-001(II) 17


2 Piping Material Specification 0 0001-01-05-02-001(II) 67
3 Welding Specification for 0 0001-01-04-02-001(II) 46
Mainline for Transportation of
Gas
4 Welding Specification Chart 0 0001-01-04-02-001-WSC1(II) 02
5 Welding Specification Chart 0 0001-01-04-02-001-WSC2(II) 01
6 Specification for Geo Textile 0 0001-01-04-02-002(II) 06
bags for Anti-Buoyancy
7 Technical Specification for Pre- 0 0001-01-04-02-003(II) 15
Commissioning and
Commissioning

STANDARD SPECIFICATION – PIPELINES

1 Specification for Longitudinal 0 S-04-02-001 36


Seam Submerged Arc Welded
Linepipe (Onshore)
2 Specification for Helical (Spiral) 0 S-04-02-002 43
Seam Submerged Arc Welded
Linepipe (Onshore)
3 Specification for Seamless Pipe 0 S-04-02-003 06
4 Specification of ERW pipe 0 S-04-02-004 34
5 Specification of External coating 0 S-04-02-005 34
– 3L PE Coating
6 Specification of Internal Epoxy 0 S-04-02-006 31
coating
7 Specification of Ball Valve 0 S-04-02-007 17
8 Specification of Plug Valve 0 S-04-02-008 14
9 Specification of Gas Powered 0 S-04-02-012 14
Valve Actuators
10 Specification for Seamless 0 S-04-02-013 07

Page 1 of 7
fittings & Flanges, Size up to DN
400 mm (16”)
11 Specification for flanges & 0 S-04-02-014 07
Welded Fittings (Size DN 450
mm (18") and above
12 Specification for Long Radius 0 S-04-02-015 10
Bends for Onshore Pipelines
13 Specification for Insulating 0 S-04-02-019 9
Joints for Onshore Pipelines
14 Specification for Casing 0 S-04-02-020 08
Insulator and End Seals
15 Specification for Field Joint 0 S-04-02-021 15
Coating (Onshore Pipeline)
16 Specification for Concrete 0 S-04-02-022 15
Weight Coating of Onshore
Pipelines
17 Specification for Repair of 0 S-04-02-023 06
Polyethylene Coating
18 Specification for Quick Opening 0 S-04-02-024 08
End Closure
19 Construction of pipelines 0 S-04-02-026 11
crossing Roads, Rail Roads and
Minor Water Crossings
20 Major Water Crossing - 0 S-04-02-027 15
Conventional Trenching
21 Specification for Pipeline 0 S-04-02-028 43
Construction (Onshore)
22 Specification for Hydrostatic 0 S-04-02-029 22
Testing of Onshore Pipelines
23 Specification for Pipeline 0 S-04-02-030 05
Markers
24 Specification for Documentation 0 S-04-02-031 09
for Pipeline Construction
25 Specification for Blasting 0 S-04-02-032 11
26 Specification for Detailed 0 S-04-02-033 17
Pipeline Route Survey (Onshore)
27 Welding Specification for 0 S-04-02-034 32
Fabrication of Piping
28 Spec. for Instructions to Vendor 0 S-04-02-035 10
for Quality Data Requirement
29 Spec. for Isuue and 0 S-04-02-036 09
Reconcilliation of Material
30 Spec. for Pipeline Information 0 S-04-02-037 06
Management system

STANDARD SPECIFICATION – PIPING

Page 2 of 7
1 Technical Notes for Pipes 0 S-05-02-001 09
2 Technical Notes for Valves 0 S-05-02-002 17
3 Technical Notes for 0 S-05-02-003 07
Butt Welded, Socket Welded
and Screwed Fittings
4 Technical Notes for Flanges, 0 S-05-02-004 05
Spectacle Blinds and Drip legs
5 Technical Notes for Bolts and 0 S-05-02-005 03
Nuts
6 Technical Notes for 0 S-05-02-006 03
Gaskets
7 Inspection and Test Plan for 0 S-05-06-001 04
Gaskets
8 Standard Specification for 0 S-05-02-011 16
Fabrication and Erection of
Piping
9 Standard Specification of "Non- 0 S-05-02-012 16
Destructive Examination of
Piping"
10 Specification for Inspection, 0 S-05-02-013 10
Flushing and Testing of Piping
System
11 Specification for Shop and Field 0 S-05-02-014 49
Painting
12 Standard specification of PMI at 0 S-14-02-001 07
Vendor's works.

STANDARD DRAWING – PIPELINES

1 Typical Right of Way for 0 S-04-01-001 02


Pipelines
2 Typical Trench Dimensions for 1 S-04-01-002 01
Pipelines
3 Pipeline Symbols 0 S-04-01-003 01
4 Topographical Symbols 0 S-04-01-004 01
5 Existing pipeline on sleeper 0 S-04-01-005 02
crossing
6 Pipeline Road/ Highway 0 S-04-01-006 01
Uneased Crossing
7 Details of casing vent and drain 0 S-04-01-007 01
8 Casing pipe details 0 S-04-01-008 01
9 Existing Under Ground Pipe 0 S-04-01-009 02
Crossing (Type-I)
10 Existing Under Ground Pipe 0 S-04-01-010 02
Crossing (Type-II)

Page 3 of 7
11 Under Ground Cable Crossing 0 S-04-01-011 02
12 Over Head Power Line Crossing S-04-01-012 02
13 Typical trench dimension for two 0 S-04-01-013 01
or more pipelines in common
trench
14 K.M. Post 0 S-04-01-014 03
15 Typical ROU boundary marker 0 S-04-01-015 02
16 Aerial marker 0 S-04-01-016 03
17 Direction marker 0 S-04-01-017 03
18 Pipeline Warning Sign 0 S-04-01-018 03
19 Navigable Waterway Pipeline 0 S-04-01-019 02
Crossing Warning Sign
20 Pipeline Road/Highway Cased 0 S-04-01-020 02
Crossing
21 Typical Stream Crossings 0 S-04-01-021 02
22 Typical Slope Breakers Details 0 S-04-01-022 03
23 Bank Protection Details for 0 S-04-01-023 03
water crossings
24 Typical details of railway 0 S-04-01-024 03
crossings
25 Select Backfill for Station 0 S-04-01-026 02
Approach
26 Slope stabilization in ghat/ hill 0 S-04-01-027 02
areas
27 Soil stabilization in hilly areas 0 S-04-01-028 03
28 Typical lined canal cased 0 S-04-01-029 02
crossing detail
29 Typical lined canal crossings 0 S-04-01-030 01
(Uncased)
30 Typical Cross section for ROU 0 S-04-01-031 01
preparation in Hilly areas

STANDARD DRAWING – PIPING

1 Jack Screw for Spectacle Blind 0 S-05-01-001 01


2 Jack Screw for Spacer & Blind 0 S-05-01-002 01
3 Vents & Drains on Lines 1-1/2” 0 S-05-01-003 01
& Below
4 Vents & Drains on Lines 2” & 0 S-05-01-004 01
Above
5 Wells Installations 1-1/2” 0 S-05-01-005 02
Diameter Traps
6 Pressure Tappings – PG, PT, PI, 0 S-05-01-006 01
PA, PC etc
7 Handle Projections for Spacers 0 S-05-01-007 01
and Blinds

Page 4 of 7
8 T-Strainer Type-1 2"-4" (150# 0 S-05-01-008 01
RF, 300# RF and RTJ, 600# RF
and RTJ)
9 T-Strainer Type-1 6"-24" 0 S-05-01-009 01
(150# RF, 300# RF and RTJ,
600# RF and RTJ)
10 Orientation of Orifice Traps 0 S-05-01-010 01
11 Stub-in Standard 0 S-05-01-011 02
12 Welding of pipe with different 0 S-05-01-012 01
thickness
13 Fillet weld details 0 S-05-01-013 01
14 Welding details for branch 0 S-05-01-014 01
connections
15 Method of cutting and 0 S-05-01-015 01
dimensions of field
manufactured concentric
reducers
16 Tolerances for fabrication 0 S-05-01-016 01
17 Pipe shoe for hot insulated C.S. 0 S-05-01-017 02
pipe, size 2" thru 8", Type-S1
(for temp. upto 343°C)
18 Pipe shoe for hot insulated C.S. 0 S-05-01-018 02
pipe, size 10" thru 30", Type-S2.
(for temp. upto 343°C)
19 Pipe saddle for bare pipe size 0 S-05-01-019 02
14” thru 48” type- S6A
20 Pipe shoe for slope line pipesize 0 S-05-01-020 02
2" thru 6" type-S9A/9B/9C
21 Low support sliding for bare and 0 S-05-01-021 02
insulated pipe size 2" thru 36"
type-L1 & L1A
22 Low support fixed for bare & 0 S-05-01-022 01
insulated pipe size 2" thru 36"
type-L3 & L3A.
23 Low support sliding for bare 0 S-05-01-023 01
pipe size 3/4" thru’ 36" type-L5
& L5A.
24 Low support sliding for bare and 0 S-05-01-024 02
insulated pipe size 2” thru 36”
Type-L6
25 Low support Fixed/Restrained 0 S-05-01-025 03
for bare and insulated pipe size
2" thru 36", type-L7 & L7A
26 Restrained Low support for bare 0 S-05-01-026 01
and insulated pipe size 2" thru
36", type-L8 & L8A

Page 5 of 7
27 Adjustable low support sliding 0 S-05-01-027 01
for pipe size 2" thru 6" type-
L10 & L10A
28 Low support sliding & fixed for 0 S-05-01-028 02
pipe size 3/4" thru 11/2"type-
L15.
29 Low support stanchion for bare 0 S-05-01-029 01
& insulated CS/AS/SS pipe
type – L16 and L16A
30 Adjustable low support with 4 0 S-05-01-030 02
bolts for pipe size 8" thru 24"
type-L17 & L17A.
31 Adjustable low support for bare 0 S-05-01-031 01
and insulated pipe size 2" thru
24". type-L18 & L18A
32 Adjustable low support with 0 S-05-01-032 02
guide & cross guide for bare
and insulated pipe size 2" thru
24" type-L19 & L19A.
33 Pipe clamp for bare pipe size 0 S-05-01-033 01
1/2" thru 24” Type C-1
34 U-bolt for bare pipe size 1/2" 0 S-05-01-034 01
thru 24" type-C4
35 Dummy pipe support for bare 0 S-05-01-035 02
pipe size 2" thru 24" type B-39
36 Dummy pipe support for 0 S-05-01-036 02
insulated pipe size 2" thru 24"
type-B40
37 Pipe support brackets type-B42 0 S-05-01-037 01
38 Guide support for bare size 1/2" 0 S-05-01-038 01
thru 24" type-G1
39 Guide support for bare size 1/2" 0 S-05-01-039 02
thru 24" type-G2 & G2A
40 Cross guide for bare pipe size 2" 0 S-05-01-040 02
thru 24" type-G3
41 Cross guide for bare pipe size 0 S-05-01-041 02
2" thru 24" type-G4.
42 Anchor for bare pipe size 2" 0 S-05-01-042 02
thru 24" type-G5.
43 Supporting arrangement for 0 S-05-01-043 01
angle & relief valves type-SP2.
44 Typical anti vibration support for 1 S-05-01-044 01
control valve-SP3.

DATASHEETS – LINEPIPE / PIPING

Page 6 of 7
1 Datasheet of Ball Valve 0 0001-01-04-04-BV-004 01
2 Datasheet of IJ 0 0001-01-04-04-IJ-005 & 006 02
3 Datasheet of Plug Valve 0 0001-01-04-04-PV-003 01
4 Data Sheets of Gate Valves of 0 0001-01-05-04-GV-001 03
Size below 2”

Page 7 of 7
ENGINEERING DESIGN BASIS
(PIPELINE ENGINEERING)

SPUR LINES OF CHAINSA – JHAJJAR PIPELINE


(PHASE-II)

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 1 of 17
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 of Industrial Areas.

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 2 of 17
Copyright GAIL – All rights reserved
1.0 INTRODUCTION
M/s GAIL (India) Ltd. proposes to lay Natural gas pipe line distribution network at
Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar, and Gurgaon regions. The
proposed Natural gas pipeline distribution network shall be of 219.1 mm (8”) OD,
approximately 27 km long and 114.3 mm (4”) OD, approximately 12 km long as
mentioned below:-

Size(Inch) X
S. No. Pipeline Tap-off Point
Length (KM)

Dharuhera Distribution network D/S of Dharuhera CGS 8” X 5.25 KM


1 Dharuhera Customer end
8” Distribution network 4” x 1.7 KM
connectivity

Bhiwadi Distribution network


2 D/S of Bhiwadi CGS 4” x 1.2 KM
Bhiwadi Customer end connectivity

Khushkhera Distribution network D/S of Khushkhera CGS 8” X 2.25 KM


3 Khushkhera Customer end
8” Distribution network 4” x 2.9 KM
connectivity

Neemrana Distribution network D/S of Neemrana CGS 8” X 3.25 KM


4
Neemrana Customer end connectivity 8” Distribution network 4” x 0.06 KM

Manesar Distribution network D/S of Manesar CGS 8” X 8.3 KM


5
Manesar Customer end connectivity 8” Distribution network 4” x 1.6 KM

D/S of Gurgaon
Gurgaon Distribution network Terminal station at 8” X 7.8 KM
Hero Honda

From 10” Hayatpur –


6 Gurgaon Line (for M/s.
Heema Engg. & M/s.
Gurgaon Customer end connectivity 4” x 4.1 KM
Neel metals) & from 8”
Distribution network
(for other customers)

These pipelines are to cater the natural gas requirement of consumers at


Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar and Khandsa/Gurgaon.
The above proposed pipelines shall have laying length as given above. The pipeline
shall be designed to handle Natural Gas & RLNG.

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 3 of 17
Copyright GAIL – All rights reserved
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
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 & 226:
Natural gas pipelines and City Gas distribution networks. 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 & 226 and
other codes/Standards referred above, requirement of ASME B 31.8/OISD 141 &
226 shall govern. In case of conflict between requirements of B31.8/OISD 141 &
226 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 this project are described briefly herein below.
4.1.1 Customer Metering stations:
S. LOCATION CUSTOMER NAME CAPACITY
NO. (MMSCMD)

1 RICO AUTO INDUSTRIES 0.02


2 DHARUHERA OMAX AUTO LTD. 0.012
3 HERO HONDA MOTORS 0.0715
4 BHIWADI SAINT GOBAIN 0.27
5 KHUSHKHERA RATHI STEELS DAKSHIN LTD. 0.017

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 4 of 17
Copyright GAIL – All rights reserved
6 RATHI BARS LTD. 0.050
7 RATHI BARS LTD. POWER 0.210
PLANT
8 RATHI SPECIAL STEEL LTD. 0.025
9 HONDA SIEL CARS INDIA LTD. 0.055
10 HINDUSTAN NATIONAL GLASS 0.030
INDUSTRIES LTD.
NEEMRANA
11 LIBERY FOOT WARE 0.033
12 PARLE BISCUITS PVT. LTD. 0.008
13 HERO HONDA MOTORS 0.075
14 NEEL METALS 0.03
15 RICO AUTO INDUSTRIES LTD. 0.05
16 SUNBEAM AUTO LTD. 0.06
GURGAON
17 SONA KOYO STEERINGS 0.022
18 HEEMA ENGINEERING 0.01
19 ROCKMAN INDUSTRIES LTD. 0.04
20 SUZUKI MOTOR CYCLE 0.02
21 RICO CASTINGS & RICO 0.022
JENFEI
22 RANE POLYMERS 0.005
23 MARUTI SUZUKI INDIA 0.36
24 SUZUKI POWER TRAIN 0.02
25 OMAX AUTO 0.0082
MANESAR
26 MUNJAL SHOWA 0.03
27 ORIENT CROFT 0.337
28 HONDA MOTOR CYCLES 0.045
29 DENSO AUTO 0.02
30 BHARTI RELAITY 0.11
31 A.G ENGINEERING 0.012

4.2 Main Pipeline


Pipeline facilities are schematically indicated in PFD, drawing Nos. 0001-00-03-01-
5004 to 0001-00-03-01-5009.

5.0 PIPELINE ROUTE

5.1 Pipeline Route

Salient features of the surveyed pipeline route (as per Industrial Location maps and
survey reports) are tabulated herein below:

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 5 of 17
Copyright GAIL – All rights reserved
Dharuhera Bhiwadi Khushkhera Neemrana Manesar Gurgaon
Size, OD 8” & 4” 8” & 4” 8” & 4” 8” & 4” 8” & 4” 8” & 4”
(Inch)
Length (Km) 5.25 & 1.7 0 & 1.2 2.25 & 2.9 3.25 & 8.3 & 1.6 7.8 &
0.06 4.1
Highest elevation
Refer Alignment sheets
above MSL (m)
Lowest elevation
Refer Alignment sheets
above MSL (m)
No. of River
Crossing , Width > 0 0 0 0 0 0
100 m
No. of Road
0 0 0 0 0 0
Crossing (NH/SH)
No. of Railway
0 0 0 0 0 0
Crossing
No. of Canal
0 0 0 0 0 0
Crossing

5.2 Terrain Details


For Terrain details and Land use pattern refer Alignment sheets attached elsewhere in
the bid document.
6.0 DESIGN DATA
6.1 Main pipeline shall be designed for conditions as follows:

PIPELINE DESIGN PARAMETER


Description Value
Industrial Distribution Networks at Dharuhera, 219.1 mm (8”) OD
Bhiwadi, Khushkhera, Neemrana, Manesar &
Gurgaon
Customer connectivity from distribution network 114.3 mm (4”) OD
Product Natural Gas/ RLNG
Design Pressure (Kg/ Cm2g) 49
2
Operating Pressure (Kg/ Cm g) 49
0
Maximum Design Temperature ( C)
i. Above Ground Section -29 to 65.0
ii. Under Ground Section -29 to 45.0
0
Operating Temperature ( C) 13 - 25
Economic Design Life (Years) 35
Corrosion Allowance (mm) 0

All terminal facilities (equipment and associated piping) shall be designed for design
and operating conditions given in the process package.
ENGINEERING DESIGN BASIS - SPECIFICATION REV-0
GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 6 of 17
Copyright GAIL – All rights reserved
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 & 226. 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 road crossings etc.
- 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 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.

Location
Type of Facility Design Factor
Class
All Station Piping 0.4
Class – 1 River / Stream Crossings
 Drilled / Bored/ Inaccessible / Open Cut 0.6
 Others 0.72
 HDD 0.5
Cased/Uncased Crossings or Parallel Encroachments 0.6
on ROW of Hard Surfaced Roads, Public Streets and
Highways
Railway Crossing 0.5

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 7 of 17
Copyright GAIL – All rights reserved
Class – 2 River / Stream Crossings
 Drilled / Bored/ Inaccessible / Open Cut 0.5
 Others 0.6
 HDD 0.5
Cased/Uncased Crossings or Parallel Encroachments 0.5
on ROW of Hard Surfaced Roads, Public Streets and
Highways
Railway Crossing 0.5
Class – 3 All 0.5
Class – 4 All 0.4
7.3 Station Piping
7.3.1 Station piping to be provided at Customer metering stations be designed in accordance
with OISD 141 & 226 / 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:
Line pipe shall conform to API 5L and Company specifications. Type of line pipe to be
used shall be SEAMLESS/EW.

Sr. LINE SIZE GRADE Class - I Class - II Class - III Class –


No. IV
1 8”(219.1 mm) X-56, 6.4 6.4 6.4 6.4
PSL-2
2 4” (114.3 mm) X-42, 6.4 6.4 6.4 6.4
PSL-2

7.4.2 Other Materials


All other materials and equipments including insulating joints, ball valves, flanges and
fittings etc. 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.
ENGINEERING DESIGN BASIS - SPECIFICATION REV-0
GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 8 of 17
Copyright GAIL – All rights reserved
7.5.2 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.

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 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
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.

S. Minimum Cover
Location
No. (m)
Industrial, commercial and residential
1.0 1.0
area
2.0 Rocky terrain 1.0
Minor water crossing/ canal/ drain/
3.0 1.5
nala/ waterways
4.0 HDD crossing of canals (below bed) 2.5
River crossings for which scour depth
5.0 1.5
is defined (below scour)
Other River crossings (Bank width >
50m) (Below Bed) 2.5 (For normal soil)
6.0
1.5 (For rocky strata)

Other River crossings (Bank width <


7.0 1.5
50m) (Below Bed)
8.0 Cased/uncased road crossing 1.2
9.0 Cased railway crossing 1.7
Drainage, ditches at roads/railway
10.0 1.2
crossings
11.0 Marshy land/Creek area 1.5

ENGINEERING DESIGN BASIS - SPECIFICATION REV-0


GAIL (INDIA) LTD PIPELINE ENGINEERING - PHASE-II
NEW DELHI 0001-01-04-03-001 (II) Page 9 of 17
Copyright GAIL – All rights reserved
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
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
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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 OTHER TECHNICAL REQUIREMENTS

8.1 Valves

All valves installed shall be gas actuated/ hand operated and with butt welding ends.
The provisions of remote operated feature shall be as per the operation and control
philosophy to be adopted for the project.

8.2 Piping
8.2.1 General

This section describes the design requirements of piping applicable for Customer
metering stations.
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.

8.2.2 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.

8.2.3 Piping layout


 Piping will be located above-ground wherever possible within the terminals.

 Piping shall be designed considering skin temperature of piping material under

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empty conditions as 650C 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
1.2m.

 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, if


required.

 Platform for filters shall be provided for maintenance/ operational access, if


required.
 Painting above ground piping and structures shall be as per specifications
enclosed in the Bid package.

8.3 Welding
Welding shall be carried out in accordance with API 1104, specification for welding and
welding charts. Butt welds shall be 100 % radiographed / UT for 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.
8.4 Hydrostatic Testing
After installation, the entire pipeline system shall be hydro tested with inhibited water.
The water shall be tested, as applicable prior to using for hydro testing. 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.

8.5 Dewatering and swabbing


Dewatering, swabbing and pre-commissioning operations shall be carried out after
hydro testing and prior to commissioning of the pipeline as per Project specifications.
For gaseous hydrocarbon pipeline the line shall be dried. After swabbing operation the
pipeline sections shall be dried as per relevant specification enclosed with the tender.
8.6 Crossings
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8.6.1 Water Crossings
All water crossing (drains etc.) shall be installed by open cut.
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.

8.6.2 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 trench less method like ramming/
boring/ jacking/ HDD /Micro Tunneling. 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 10” / 18”. The
crossing angle shall be as close to 90º as possible. Casing insulators and end seals shall
be provided to ensure electrical isolation of carrier pipe and casing pipe.

8.6.4 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.
8.7 Valves
8.7.1 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 minimize 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 centre line of the rim of the hand wheel on a
horizontal shaft or centre of power actuator as approximately 1.0 m above the finished
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ground level.
Minimum size of any tapping from the underground pipeline shall be 2" NB and shall be
provided with an isolation ball valve located at a minimum distance from the pipeline.
8.8 Branch Connections
All branch connections or side tap shall be as per PMS.
8.9 Pipeline Bends
In order to accommodate changes in vertical and horizontal alignment, pre-fabricated
bends shall be used. Miter bends shall not be used for change in direction.

8.10 Specifications
All procurement of materials shall be as per Piping Material Specification (PMS) and
specifications indicated in PMS.

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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:

1. Line Pipes
API 5L Specification for Line pipe
API 5L1 Recommended Practice for Railroad Transportation
of Line pipe
API 5LW Recommended Practice for Transportation of Line
pipe on Barges & Marine Vessels
2. Valves
API 6D Specification for pipeline valves (Steel Gate, Plug,
Ball and Check Valves)
API 602 Compact Steel Gate Valves-Flanged, Threaded,
Welding & Extended Body ends.
ASTM A694 Forgings, Carbon & Alloy steel for Pipe Flanges,
Fittings, Valves & parts for High Pressure
Transmission Service.
MSS-SP-6 Finishes for Contact Faces of connecting End
Flanges of Ferrous Valves and Fittings.
MSS-SP-25 Standard Marking System for Valves, Fittings &
Unions
BS 5351 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
ANSI 16.20
Flanges
ASTM A105 Forgings, Carbon Steel for Piping Components
ASTM A193 Carbon & Alloy Steel Bolts & Studs for High
Temperature Service
API 601 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 Butt Welding Ends
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ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy
Steel for Moderate and Elevated Temperatures
ASTM A694 Forgings, Carbon & Alloy Steel for Pipe Flanges,
Fittings, Valves & Parts for High Pressure
Transmission Service.
MSS-SP-75 Specification for High Test Wrought Butt Welding
Fittings
MSS-SP-97 Integrally Reinforced Forced Branch Outlet Fittings
– Socket Welding, Threaded and Butt Welding
Ends.
PFI-ES-24 Pipe Bending Methods, Tolerances, Processes &
Material Requirements
4. Testing & Welding
ANSI/AWS D1.1 Structural Steel Welding
Standard for Welding Pipelines and Related
API 1104
Facilities
AWS A3.0 Welding Terms and Definitions
AWS A5.1 Welding Electrodes
AWS A5.5 Specification for Low Alloy Steel Covered Arc
Welding Electrodes
ASTM E165 Liquid Dye Penetrant Inspection of Pipeline Welds
ASTM A370 Standard Methods and Definitions for Mechanical
Testing of Steel Products.
ASTM E18 Standard Hardness Test for Metals
ASTM E23 Standard for Impact Test for Metals
ASTM E84 Standard Test Method for Micro-hardness of Metals
ASTM E92 Standard Test Method for Vickers Hardness of
Metallic Materials
ASTM E110 Standard Test Method Indentation Hardness for
Metallic Materials by Portable Hardness Testers
ASTM E709 Standard Guides for Magnetic Particle Examination
MSS-SP-53 Quality Standard for Steel Casting & Forging-
Magnetic Particle Method
MSS-SP-54 Quality Standard for Steel Casting & Forging-
Radiographic Examination
MSS-SP-55 Quality Standard for Steel Castings & Forgings-
Visual Method.
5. Surface Preparation, Painting and Coating
SIS-05-59 Pictorial Surface Preparation Standards for Painting

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Steel Surfaces

SSPC-SP-01 Solvent Cleaning

SSPC-SP-03 Power Tool Cleaning


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
Measurement of Pipeline Dry Film Coating
ASTM E12
Thickness

ASTM-G6 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 Adhesive Tapes
for Electrical Purposes
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


(PHASE – II)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 1 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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

ANNEXURE- MATERIAL SPECIFICATIONS FOR PIPING CLASSES


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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


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1.0 SCOPE

1.1 It is proposed to install a Natural gas pipe lines from Metering Terminal Station at Dharuheda ,
Bhiwadi, Khushikhera, Neemrana, Manesar and Gurgaon to initially cater the demand of
consumers in Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar and Gurgaon regions. The
proposed Natural gas pipeline shall be of 457 mm (8”) OD, approximately 27.00 km long and (4”)
OD, approximately 12.00 km.

The scope shall include piping and tap-off points after CGS at various locations in Industrial Area
of Dharuheda, Bhiwadi, Khushikhera, Neemrana, Manesar and Gurgaon and at various Metering
station at customer end.

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.

A – Class 150

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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-SP-
97. Fittings not covered in ASME B16.9 and MSS-SP-97 shall conform to manufacturer’s standard.

7.8 Fittings thickness tolerances shall match pipe thickness tolerance.

8.0 BENDS

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8.1 Unless otherwise specified for process piping, elbow of radius R = 1.5 D shall only be used.
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/ manufacturer’s
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 ¼“ to 1” : UNC-2B

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Nuts for stud bolts dia 1⅛ %” to 3¼ : 8UN-2B

11.4 Threads for stud bolts shall be as per ASME B 1.1, as follows:

Stud bolts dia ¼“ to 1” : UNC-2A

Stud bolts dia 1⅛ %” to 3¼ : 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 (1½” and below)

Design STD. for Process lines

Gate Valves : API 602


Globe Valves : BS 5352
Ball Valves : BS 5351
Plug Valves : BS 5353

Flanged/ Butt Welded end valves (2” and above)

Design STD. for Process Lines

Gate Valves : API 6D


Globe Valves : BS 1873
Check Valves : API 6D

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Ball Valves : API 6D
Plug Valves : API 6D

13.8 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

Quick opening end closure to be installed on scraper traps (if applicable) 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, insulating joints, etc. shall be as per specifications attached elsewhere.

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


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NEW DELHI 0001-01-05-02-001-Phase –II
Sl. SECTION TPIPE MATERIAL METHOD OF W.T. (mm)
No. DIA (API 5L) MANUFACTURE
(INCH)

NEW DELHI
LINE PIPE Class Class Class Class -
–I – II – III IV

GAIL (INDIA) LTD


1. Industrial Area Network at Dharuhera, Bhiwadi, 8 X – 56, PSL-2 SEAMLESS, EW 6.4 6.4 6.4 6.4
Khushikhera, Neemrana, Manesar and Gurgaon
2. Customer Connectivity up to Customer Metering 4 X – 42, PSL-2 SEAMLESS ,EW 6.4 6.4 6.4 6.4
Skid

(PHASE –II)
TABLE -1

PIPING MATERIAL SPECIFICATION


SPECIFICATION

0001-01-05-02-001-Phase –II
REV-0
Page 8 of 67
TABLE – 2
Class Service Design Condition C.A. (mm) Pipe Design
Pressure Temp. Material Code
(Kg/cm2 ) (0 C)
D1A Hydrocarbon 99.93 65 1.5 API 5L X – ASME B
Gas 52/ ASTM 31.8 /
A 106 GR- OISD –
B / Gr.B 141
(Charpy) /
Gr. B PSL-
2 as
applicable
B1A Hydrocarbon 49.0 65 1.5 ASTM A ASME B
Gas 106 GR- B 31.8 /
/ Gr.B OISD –
(Charpy) / 141/ 226
Gr. B PSL-
2 as
applicable
A1A Hydrocarbon 19 65 1.5 ASTM A ASME B
Gas 106 GR- B 31.8 /
/ Gr.B OISD –
(Charpy) / 141 / 226
Gr. B PSL-
2 as
applicable
A3A Utilities 10.5 65 1.5 IS-1239 ASME B
(BLACK) 31.3
J2A Potable Water 10.5 65 0 IS-1239 ASME B
(Galv) 31.3
A93A Fire Water 18.9 65 1.5 IS-1239 ASME B
(Black)/ 31.3
IS-3589
GR 410 as
applicable

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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 9 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE A
PIPING MATERIAL SPECIFICATION
(A1A - CLASS 150#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 10 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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 LETHAL-


HYDROCARBONS, 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. 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.
6. FOR VALVES, REFER RESPECTIVE VALVE DATA SHEETS. FOR HANDLE PROJECTION REFER
STD. DRG-S-05-01-007.
7. SPECIAL NOTES

ITEM SIZE DESCRIPTION

MAINTENANCE FLANGED TO BE KEPT MINIMUM


ALL
JOINTS
PIPE JOINTS 1.5” & BELOW SW COUPLING

2.0” & ABOVE BUTT WELDED

DRAINS 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

VENTS 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

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.S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 11 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
72 72
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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
BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)


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 T 10
8.0 T T 8.0
6.0 T T T 6.0
5.0 5.0
4.0 T T T T 4.0
3.5 3.5
3.0 T T T W W 3.0
2.5 2.5
2.0 T T T W W W 2.0
1.5 T T S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S 1.0
0.75 T T T S S S S S S 0.75
0.5 T T T T S S S S S S 0.5
0.500

0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

10.00

RUN PIPE (SIZES IN INCH) – A1A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 12 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET

Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)

Pipe Group (A1A)

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 BE, SEAMLESS


(CHARPY)

PIPE 03.000 03.000 STD B 36.10 ASTMA106 GR.B BE, SEAMLESS


(CHARPY)

PIPE 04.000 04.000 STD B 36.10 ASTMA106 GR.B BE, SEAMLESS


(CHARPY)

PIPE 06.000 06.000 STD B 36.10 ASTMA106 GR.B BE, SEAMLESS


(CHARPY)

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 M B 36.10 ASTMA 106 GR.B PBE, SEAMLESS

NIPPLE 01.000 01.500 M B 36.10 ASTMA 106 GR.B PBE, SEAMLESS

Flange Group (A1A)

FLNG.WN 00.500 01.500 M B-16.5 ASTM A 105 150, RF/125AARH

FLNG.WN 02.000 24.000 M 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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 13 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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

Fitting Group (A1A)

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 BW, 1.5D


(CHARPY)

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 M B-16.9 ASTM A234,GR. WPB BW, 1.5D


(CHARPY)

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 M B-16.9 ASTM A234,GR.WPB BW


(CHARPY)

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 BW


(CHARPY)

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


(CHARPY)

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


(CHARPY)

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 M B-16.9 ASTM A234,GR. WPB BW


(CHARPY)

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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 14 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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 (A1A)

SOCKOLET 00.500 0.750 MSS- ASTM A 105 SW, 6000


SP97

SOCKOLET 01.000 01.500 MSS- ASTM A 105 SW, 3000


SP97

WELDOLET 02.000 10.000 M, MSS- ASTMA 105 (CHARPY) BW


XXS SP97

Valves Group (A1A)

VLV.GATE 00.500 01.500 API-602 BODY-ASTM A SW,800, 3000,B-


105, TRIM-STELLITED, 16.11
STEM13%CR. STEEL

VLV.GLOBE 00.500 01.500 BS-5352 BODY-ASTM A SW,800, 3000,B-


105,TRIM-STELLITED, 16.11
STEM13%CR STEEL

VLV.CHECK 00.500 01.500 BS-5352 BODY-ASTMA SW,800, 3000, B-


105,TRIM-STELLITED 16.11

Bolt Group (A1A)

BOLT.STUD 00.500 24.000 B18.2 BOLT: 193 GR.B7,NUT:


A194 GR. 2H

Gasket Group (A1A)

GASKET 00.500 24.000 B16.20- SP,WND, SS316+CAF SPIRAL, 150


ANSI B
16.5

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 15 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE B

PIPING MATERIAL SPECIFICATION


(A3A - CLASS 150#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 16 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : A3A, 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 UTILITIES (ABOVE GROUND) – COOLING WATER, INERT GAS,
INSTRUMENT AIR, CONDENSATE

NOTES

1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.

2. NDT REQUIREMENT AS PER GAIL STANDARD S-05-02-012

3. FOR VALVES REFER VALVE DATA SHEET

SPECIAL NOTES

ITEM SIZE DESCRIPTION

MAINTENANCE FLANGED TO BE KEPT MINIMUM


ALL
JOINTS
PIPE JOINTS 1.5” & BELOW SW COUPLING 3000 #

2.0” & ABOVE BUTT WELDED

DRAINS 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

VENTS 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.
S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 17 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
72 72
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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
BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)


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 T 6.0
5.0 5.0
4.0 T P 4.0
3.5 3.5
3.0 T P P 3.0
2.5 2.5
2.0 T P P P 2.0
1.5 T T H H H 1.5
1.25 1.25
1.0 T T H H H H 1.0
0.75 T T T H H H H 0.75
0.5 T T T T H H H H 0.5
0.500

0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

(A3A)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 18 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET

Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)

Pipe Group (A3A)

PIPE 00.500 1.50 HVY IS-1239- IS-1239 (BLACK) PE, C. WELDED


I

PIPE 02.000 06.000 HVY IS-1239- IS-1239 (BLACK) PE, C. WELDED


I

NIPPLE 00.500 01.50 HVY IS-1239- IS-1239 (BLACK) PE, C. WELDED


I

Flange Group (A3A)

FLNG.SW 00.500 01.500 M B-16.5 ASTM A 105 150,


RF/125AARH

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} 150,


RF/125AARH
FLNG.FIG8 00.500 01.500 B-16.48 ASTM A 105 150,
RF/125AARH

FLNG.FIG8 02.000 06.000 B-16.5 ASTM A105 (CHARPY) 150,


RF/125AARH
Fitting Group (A3A)

ELBOW.90 00.500 01.500 B-16.11 ASTM A 105 SW,3000

ELBOW.90 02.00 06.00 STD B-16.9 ASTM A 234 GR. WPB BW, 1.5D
(CHARPY)

ELBOW.45 00.500 01.50 B-16.11 ASTM A 105 SW, 3000

ELBOW.45 02.000 06.000 STD B-16.9 ASTM A 234 GR. WPB BW, 1.5D
(CHARPY)

T.EQUAL 00.500 01.50 B 16.11 ASTM A 105 SW, 3000

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 19 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
T.EQUAL 02.00 06.00 STD B 16.11 ASTM A 234 GR. WPB BW
(CHARPY)

T.RED 00.500 01.500 B-16.11 ASTM A 105 SW, 3000

T.RED 02.000 06.00 STD B-16.9 ASTM A 234 GR. WPB BW


(CHARPY)

REDUC.CONC 02.000 06.000 STD,STD B-16.9 ASTM A234,GR. WPB BW


(CHARPY)

REDUC.ECC 02.000 06.000 STD,STD B-16.9 ASTM A234,GR. WPB BW


(CHARPY)

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 STD B-16.9 ASTM A234,GR. WPB BW


(CHARPY)

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

Valves Group (A3A)

VLV.GATE 00.250 01.500 API-602 BODY-ASTM A SW,800, 3000,B-


105, TRIM-STELLITED, 16.11
STEM13%CR. STEEL

VLV.GATE 02.00 24.00 API-600 BODY-ASTM A FLGD, 150, B


216, WCB, TRIM- 16.5,
STELLITED, STEM13%CR. RF/125AARH
STEEL

VLV.GLOBE 00.25 01.500 BS-5352 BODY-ASTM A SW,800, 3000,B-


105,TRIM-STELLITED, 16.11
STEM13%CR STEEL

VLV.GLOBE 02.00 16.00 BS-1873 BODY-ASTM A FLGD, 150, B


216, WCB, TRIM- 16.5,
STELLITED, STEM13%CR. RF/125AARH
STEEL

VLV.CHECK 00.250 01.500 BS-5352 BODY-ASTMA SW,800, 3000, B-


105,TRIM-STELLITED 16.11

VLV.CHECK 02.00 24.00 BS 1868 BODY-ASTM A 216, GR. FLGD, 150, B


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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 20 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
VLV.BALL 00.500 16.00 BS-5351 BODY-ASTM A FLGD, 150, , B
105,A 216 GR. WCB TRIM- 16.5,
BODY SEAT - RPTFE RF/125AARH

VLV.BTRFLY 03.500 24.00 BS-5155 BODY-ASTM A 216 GR., WAFL, 150, B-


WCB, TRIM- 13% CR. 16.5
STEEL WAF/125AARH

Bolt Group (A3A)

BOLT.STUD 00.500 6.000 B18.2 BOLT: A 307, GR. B, NUT:


A 563 GR.B

Gasket Group (A3A)

GASKET 00.500 6.000 B16.21- IS-2712- GR.-W/3 RING, 150, 2 MM


ANSI B
16.5

TRAP/ STRAINER GROUP (A3A)

TRP 00.500 1.50 MANF’S B:A105, T:13%CR, S:SS304 FLGD,


STD THRMDNMC,
150, RF/125AARH

TRP 01.500 6.000 MANUF B:A285GR.C; INT: SS304 CONETYPE, 150,


STD FF/125 AARH

TRP 00.500 1.500 MANUF B:A105; INT: SS304 SW, Y-TYPE, 800
STD

TRP 02.00 6.000 M MANUF B:A234GR. WPB; INT: BW, T - TYPE


STD SS304

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 21 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE C

PIPING MATERIAL SPECIFICATION


(B1A - CLASS 300#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 22 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : (B1A), 300 #

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 LETHAL-
HYDROCARBONS, AROMATICS, AMMONIA, SWEET GAS, FLUSHING OIL AND OTHER
UTILITIES -MP CONDENSATE, INSTRUMENT AIR, PLANT AIR, NITROGEN, AMMONIA GAS
ETC.

NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:

RADIOGRAPHY : 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. 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.

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
DRAINS ON LINES ≤1.5” REFER GAIL STD.S-05-01-003
ON LINES ≥2.0” AS PER P&ID OR 0.75”; GAIL STD. S-05-01-004
VENTS 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. S-
05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 23 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
72 72
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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
BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)


36 36
34 34
32 32
30 30
28 28
26 26
24 24
22 22
20 T 20
18 T T 18
16 T T T 16
14 T T T T 14
12 T T T T T 12
10 T T T T T T 10
8.0 T T T T T T T 8.0
6.0 T T T T T T W W 6.0
5.0 5.0
4.0 T T T T W W W W W 4.0
3.5 3.5
3.0 T T T W W W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W W W 2.0
1.5 T T S S S S S S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S S S S S S 1.0
0.75 T T T S S S S S S S S S S S 0.75
0.5 T T T T S S S S S S S S S S S 0.5
10.000

12.000

14.000

16.000

18.000

20.000
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

(B1A)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 24 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET

Lower Upper
Sch./
Item Type Size Size Dim. STD Material Description
Thk
(Inch) (Inch)

Pipe Group (B1A)

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 06.000 STD B 36.10 ASTMA106 GR.B (CHARPY) 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 M B 36.10 ASTM A 106 GR.B PBE, SEAMLESS

NIPPLE 01.000 01.500 M B 36.10 ASTM A 106 GR.B PBE, SEAMLESS

Flange Group (B1A)


FLNG.SW 00.500 01.500 M B-16.5 ASTM A 105 300,
RF/125AARH

FLNG.WN 02.000 16.000 M B-16.5 ASTM A 105 (CHARPY) 300,


RF/125AARH

FLNG.WN 18.000 20.000 M 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} 300,


RF/125AARH
FLNG.FIG8 00.500 01.500 B-16.48 ASTM A 105 300,
RF/125AARH

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 25 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
FLNG.FIG8 02.000 08.000 B-16.48 ASTM A105 (CHARPY) 300,
RF/125AARH
SPCR &BLIND 10.000 20.000 B-16.48 ASTM A105 (CHARPY) 300,
RF/125AARH
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 M B-16.9 ASTM A 234,GR. WPB BW, 1.5D


CHARPY)

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


CHARPY)

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 M B-16.9 ASTM A234, GR. WPB BW, 1.5D
CHARPY)

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

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 M B-16.9 ASTM A234,GR.WPB BW


(CHARPY)

T.EQUAL 18.000 20.000 M B – 16.9 ASTM A234,GR.WPB BW


(CHARPY)

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. BW


WPB(CHARPY)

T.RED 18.000 20.000 M, M B – 16.9 ASTM A234,GR. BW


WPB(CHARPY)

REDUC.CONC 02.000 16.000 M,M B-16.9 ASTM A234,GR. BW


WPB(CHARPY)

REDUC.CONC 18.000 26.000 M,M B-16.9 ASTM A234,GR. BW


WPB(CHARPY)

REDUC.ECC 02.000 16.000 M,M B-16.9 ASTM A234,GR. BW


WPB(CHARPY)

REDUC.ECC 18.000 20.000 M,M B – 16.9 ASTM A234,GR. BW


WPB(CHARPY)

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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 26 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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 M B-16.9 ASTM A234,GR. WPB BW


(CHARPY)

CAP 18.000 20.000 M B – 16.9 ASTM A234,GR. WPB BW


(CHARPY)

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 M, MSS-SP97 ASTMA 105 (CHARPY) BW


XXS

Valves Group (B1A)

VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 105, TRIM- SW,800, 3000,B-


STELLITED, STEM13%CR. 16.11
STEEL

VLV.GATE 02.000 20.000 API-6D BODY-ASTM A 216 GR. WCB FLGD, 300, B-
TRIM-STELLITED, STEM 13% 16.5, RF/ 125
CR. STEEL AARH

VLV.GLOBE 00.500 01.500 BS-5352 BODY-ASTM A 105,TRIM- SW,800, 3000,B-


STELLITED, STEM13%CR 16.11
STEEL

VLV.GLOBE 02.000 20.000 BS-1873 BODY-ASTM A 216 GR. WCB FLGD, 300, B-
TRIM-STELLITED, STEM 13% 16.5, RF/ 125
CR. STEEL AARH

VLV.CHECK 00.500 01.500 BS-5352 BODY-ASTMA SW,800, 3000, B-


105,TRIM-STELLITED 16.11

VLV.CHECK 2.000 20.000 API -6D BODY-ASTM A 216 GR. WCB FLGD, 300, B-
TRIM-STELLITED, STEM 13% 16.5, RF/ 125
PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0
GAIL (INDIA) LTD (PHASE –II) Page 27 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CR. STEEL AARH

VLV.BALL 00.500 01.500 BS-5351 BODY-ASTM A 105,TRIM- FLGD, 300, B-


SEAT RPTFE 16.5, RF/ 125
AARH

VLV.BALL 02.000 20.000 API-6D BODY-ASTM A 216 GR. WCC/ FLGD, 300, B-
A234 GR WPC, TRIM-SEAT 16.5, RF/ 125
AISI 4140+0.003” ENP/ AISI 410 AARH

VLV.BALL 02.000 02.000 API-6D BODY-ASTM A 216 GR. WCC/ BW, 300, B-
A234 GR WPC, TRIM-SEAT 16.25, RF/ 125
AISI 4140+0.003” ENP/ AISI 410 AARH

VLV.PLUG 00.500 01.500 BS-5353 BODY-ASTM A 105, PLUG-A SW,800 3000, B-


105 +0.003” ENP 16.11

VLV.PLUG 02.000 20.000 API-6D BODY-ASTM A 216 GR. WCB FLGD, 300, B-
PLUG-A 216 GR. WCB+0.003” 16.5, RF/ 125
ENP 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 B16.20- SP,WND, SS316+CAF SPIRAL, 300
ANSI B
16.5

GASKET 26.000 20.000 B16.20- SP,WND, SS316+CAF SPIRAL, 300


ANSIB
16.5

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 28 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE D

PIPING MATERIAL SPECIFICATION


(D1A - CLASS 600#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 29 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : D1A, 600 #

BASE MATERIAL : CARBON STEEL

CORROSION ALLOWANCE : 1.5 MM

SPECIAL REQUIREMENT : NON IBR

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

SERVICE - REGASIFIED LNG (R-LNG) / Natural Gas

NOTES

1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.

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 : ALL BUTT WELDS - 100%


MPI : SOCKET WELDS - 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
CONNECTION SHALL BE AS PER BRANCH CONNECTION TABLE GIVEN ON NEXT PAGE. THE
BRANCH DETAILS INDICATED IN APPLICABLE STANDARD SHALL BE IGNORED.

12. CORROSION ALLOWANCE OF 1.5 MM HAS BEEN CONSIDERED FOR TERMINAL PIPING AND 0.0
MM FOR MAIN PIPELINE

13. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND – REFER STD. DRG.-
S-05-01-007

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 30 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
14. SPECIAL NOTES - D1A

ITEM SIZE DESCRIPTION

MAINTENANCE JOINTS ALL FLANGED, TO BE KEPT MINIMUM


PIPE JOINTS 1.5” & BELOW SW COUPLING

2.0” & ABOVE BUTT WELDED

DRAINS 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

VENTS 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-05-01-003

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.
S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 31 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
72 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
BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)


36 36
34 34
32 32
30 T 30
28 28
26 T T 26
24 T T T 24
22 T T T T 22
20 T T T T T 20
18 T T T T T T 18
16 T T T T T T T 16
14 T T T T T T T T 14
12 T T T T T T T T T 12
10 T T T T T T T T W T 10
8.0 T T T T T T T W W W W 8.0
6.0 T T T T T T W W W W W W 6.0
5.0 5.0
4.0 T T T T W W W W W W W W W 4.0
3.5 3.5
3.0 T T T W W W W W W W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W W W W W W W 2.0
1.5 T T S S S S S S S S S S S S S S 1.5
1.25 1.25
1.0 T T T S S S S S S S S S S S S S S 1.0
0.75 T T T T S S S S S S S S S S S S S S 0.75
0.5 T T T T S S S S S S S S S S S S S S S 0.5
10.000

12.000

30.000
14.000

16.000

18.000

20.000

22.000

24.000

26.000

28.000
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

RUN PIPE (SIZES IN INCH) – D1A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 32 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET

Lower Upper
Sch./
Item Type Size Size Dim. STD Material Description
Thk
(Inch) (Inch)

Pipe Group (D1A)

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 2 API 5L API 5L GR.X-52 PSL2 BE, SAW

NIPPLE 00.500 00.750 M B 36.10 ASTM A 106 GR.B PBE,SEAMLESS

NIPPLE 01.000 01.500 M B 36.10 ASTM A 106 GR.B PBE,


SEAMLESS

Flange Group (D1A)

FLNG.SW 00.500 01.500 M B-16.5 ASTM A 105 600,


RF/125AARH

FLNG.WN 02.000 8.000 M B-16.5 ASTM A 105 (CHARPY) 600,


RF/125AARH

FLNG.WN 10.000 24.000 M B- 16.5 ASTM A 694 GR. F-52 (CHARPY) 600, RF/125AARH

FLNG.WN 28.000 30.000 M B-16.47-A ASTM A 694 GR. F-52 (CHARPY) 600,
RF/125AARH

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 33 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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} 600,


RF/125AARH
FLNG.BLIND 26.000 30.000 B16.47A ASTM A105 (CHARPY} 600,
RF/125AARH
FLNG.FIG8 00.500 01.500 B-16.48 ASTM A 105 600,
RF/125AARH

FLNG.FIG8 02.000 08.000 B-16.48 ASTM A105 (CHARPY) 600,


RF/125AARH
SPCR &BLIND 10.000 24.000 B-16.48 ASTM A105 (CHARPY) 600,
RF/125AARH
SPCR &BLIND 26.000 30.000 MNF’S ASTM A516 GR.70 (CHARPY) 600,
STD 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 M B-16.9 ASTM A 234,GR. WPB (CHARPY) BW, 1.5D

ELBOW.90 10.000 30.000 M 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 M B-16.9 ASTM A234, GR. WPB (CHARPY) BW, 1.5D

ELBOW.45 10.000 30.000 M MSS-SP75 MSS-SP75 GR.WPHY-52 BW, 1.5D

PIPE BEND 18.000 30.000 M 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 M B-16.9 ASTM A234,GR.WPB (CHARPY) BW

T.EQUAL 10.000 30.000 M 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 ASTM A234,GR. WPB(CHARPY) 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 ASTM A234,GR. WPB(CHARPY) BW

REDUC.ECC 10.000 30.000 M,M MSS-SP75 MSS-SP75 GR.WPHY-52 BW

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 34 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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 M B-16.9 ASTM A234,GR. WPB (CHARPY) BW

CAP 10.000 30.000 M 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

O’ let group (D1A)

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, MSS-SP97 ASTMA 105 (CHARPY) BW


XXS

WELDOLET 18.000 20.000 M, MSS-SP97 ASTMA 694 GR. F-52 (CHARPY) BW


M

Valves Group (D1A)

VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 105, TRIM- SW,800, 3000,B-


STELLITED, STEM13%CR. 16.11
STEEL

VLV.GLOBE 00.500 01.500 BS-5352 BODY-ASTM A 105,TRIM- SW,800, 3000,B-


STELLITED, STEM13%CR STEEL 16.11

VLV.CHECK 00.500 01.500 BS-5352 BODY-ASTMA SW,800, 3000, B-


105,TRIM-STELLITED 16.11

VLV.BALL 00.500 01.500 BS-5351 BODY-ASTM A 105,TRIM-SEAT FLGD, 600, B-


RPTFE 16.5, RF/ 125
AARH

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 35 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
VLV.BALL 02.000 24.000 API-6D BODY-ASTM A 216 GR. WCC/ FLGD, 600, B-
A234 GR WPC, TRIM-SEAT AISI 16.5, RF/ 125
4140+0.003” ENP/ AISI 410 AARH

VLV.BALL 26.000 30.000 API-6D BODY-ASTM A 216 GR. WCC/ BW, 600, B-
A234 GR WPC, TRIM-SEAT AISI 16.25, RF/ 125
4140+0.003” ENP/ AISI 410 AARH

VLV.BALL 02.000 30.000 API-6D BODY-ASTM A 216 GR. WCC/ BW, 600, B-
A234 GR WPC, TRIM-SEAT AISI 16.25, RF/ 125
4140+0.003” ENP/ AISI 410 AARH

VLV.PLUG 00.500 01.500 BS-5353 BODY-ASTM A 105, PLUG-A 105 SW, 800 3000, B-
+0.003” ENP 16.11

VLV.PLUG 02.000 24.000 API-6D BODY-ASTM A 216 GR. WCB FLGD, 600, B-
PLUG-A 216 GR. WCB+0.003” 16.5, RF/ 125
ENP AARH

VLV.PLUG 02.000 24.000 API-6D BODY-ASTM A 216 GR. WCB BW, 600, B-16.5,
PLUG-A 216 GR. WCB+0.003” RF/ 125 AARH
ENP

Bolt Group(D1A)

BOLT.STUD 00.500 30.000 B18.2 BOLT: 193 GR.B7,NUT: A194 GR.


2H

Gasket Group(D1A)

GASKET 00.500 24.000 B16.20- SP,WND, SS316+CAF SPIRAL, 600


ANSI
B16.5

GASKET 26.000 30.000 B16.20- SP,WND, SS316+CAF SPIRAL, 600


ANSI
B16.47A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 36 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE E

PIPING MATERIAL SPECIFICATION


(A4A - CLASS 150#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 37 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : A4A, 150 #

BASE MATERIAL : CARBON STEEL

CORROSION ALLOWANCE : 1.5 MM

SPECIAL REQUIREMENT : LOW TEMPERATURE SERVICE

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

SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND
UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC.

NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:

RADIOGRAPHY : ALL BUTT WELDS - 100%

MPI : SOCKET WELDS - 100%

3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4. IMPACT TESTING IS REQUIRED

5. 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.

6. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

7. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC.
S-05-01-007
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
DRAINS 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
VENTS 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-05-01-003


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.
S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 38 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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50 50
48 48
46 46
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42 42
40 40
38 38
BRANCH PIPE (SIZE IN INCHES)

BRANCH PIPE (SIZE IN INCHES)


36 36
34 34
32 32
30 30
28 28
26 26
24 24
22 22
20 20
18 18
16 16
14 T 14
12 T T 12
10 T T T 10
8.0 T T T T 8.0
6.0 T T T T T 6.0
5.0 5.0
4.0 T T T T W W 4.0
3.5 3.5
3.0 T T T W W W W 3.0
2.5 2.5
2.0 T T T W W W W W 2.0
1.5 T T S S S S S S S 1.5
1.25 1.25
1.0 T T S S S S S S S S 1.0
0.75 T T T S S S S S S S S 0.75
0.5 T T T T S S S S S S S S 0.5
10.000

12.000

14.000
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

RUN PIPE (SIZES IN INCH) A4A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 39 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Lower Upper
Sch./
Item Type Size Size Dim. STD Material Description
Thk
(Inch) (Inch)

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 M B 36.10 ASTM A 333 GR.6 PBE,SEAMLESS

NIPPLE 01.000 01.500 M B 36.10 ASTM A 333 GR.6 PBE, SEAMLESS

Flange Group (A4A)


FLNG. WN 00.500 14.000 M 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 ASME- ASTM A 350 GR. LF2 150, FF/125 AARH
B16.48

SPCR &BLIND 10.000 14.000 ASME- ASTM A 350 GR. LF2 150, FF/125 AARH
B16.48
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 M 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 M 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 M 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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 40 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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 M 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 M, MSS-SP97 ASTM A 350 GR.LF2 BW


XXS

Valves Group (A4A)

VLV.GATE 00.500 01.500 API-602 BODY-ASTM A 350 GR. LF2, SW,800, 3000,B-
TRIM-STELLITED, STEM SS-304 16.11

VLV.GLOBE 00.500 01.500 BS-5352 BODY-ASTM A 350 GR.LF2, SW,800, 3000,B-


TRIM-STELLITED, STEM SS304 16.11

VLV.CHECK 00.500 01.500 BS-5352 BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-


TRIM-STELLITED 16.11

Bolt Group (A4A)


BOLT.STUD 00.500 14.000 B18.2 BOLT: A 320 GR.L7, NUT:A194
GR.4

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 41 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
Gasket Group (A4A)
GASKET 00.500 14.000 B16.20- SP,WND, SS316+CAF SPIRAL, 150
ANSI
B16.5

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 42 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE F

PIPING MATERIAL SPECIFICATION


(B4A - CLASS 300#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 43 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : B4A, 300 #

BASE MATERIAL : CARBON STEEL

CORROSION ALLOWANCE : 1.5 MM

SPECIAL REQUIREMENT : LOW TEMPERATURE SERVICE

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

SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND
UPTO -45 DEG C.HYDROCARBONS, XYLENE, PROPYLENE, LPG, METHANOL, NH3, GAS FLARE ETC.

NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:

RADIOGRAPHY : ALL BUTT WELDS - 100%

MPI : SOCKET WELDS - 100%

3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4. IMPACT TESTING IS REQUIRED

5. 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.

6. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

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

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
DRAINS 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
VENTS 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.
S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 44 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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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 T 14
12 T T 12
10 T T T 10
8.0 T T T T 8.0
6.0 T T T T T 6.0
5.0 5.0
4.0 T T T T W W 4.0
3.5 3.5
3.0 T T T W W W W 3.0
2.5 2.5
2.0 T T T W W W W W 2.0
1.5 T T S S S S S S S 1.5
1.25 1.25
1.0 T T T S S S S S S S 1.0
0.75 T T T T S S S S S S S 0.75
0.5 T T T T S S S S S S S S 0.5
10.000

12.000

14.000
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

RUN PIPE (SIZES IN INCH) – B4A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 45 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)

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 M B 36.10 ASTM A 333 GR.6 PBE,SEAMLESS

NIPPLE 01.000 01.500 M B 36.10 ASTM A 333 GR.6 PBE, SEAMLESS

Flange Group (B4A)

FLNG. SW 00.500 1.50 M B-16.5 ASTM A 350 GR. LF2 300, RF/125 AARH

FLNG. WN 02.000 14.000 M 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 ASME- ASTM A 350 GR. LF2 300, FF/125 AARH
B16.48

SPCR &BLIND 10.000 14.000 ASME- ASTM A 350 GR. LF2 300, FF/125 AARH
B16.48
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 M 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 M 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 M B-16.9 ASTM A 420 GR.WPL6 BW

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 46 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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, B-16.9 ASTM A 420 GR.WPL6 BW


M

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- ASTM A 350 GR.LF2 PBE


3799

SWAGE.ECC 00.500 03.000 M,M BS- ASTM A 350 GR.LF2 PBE


3799

CAP 02.000 14.000 M 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 MSS- ASTM A 350 GR.LF2 SW, 6000


SP97

SOCKOLET 01.000 01.500 MSS- ASTM A 350 GR.LF2 SW, 3000


SP97

WELDOLET 02.000 4.000 M, MSS- ASTM A 350 GR.LF2 BW


XXS SP97

Valves Group (B4A)

VLV.GATE 00.500 01.500 API- BODY-ASTM A 350 GR. LF2, SW,800, 3000,B-16.11
602 TRIM-STELLITED, STEM SS-
304

VLV.GATE 00.200 24.000 API- BODY-ASTM A 352 GR. LCB, FLGD,300, B16.5,
600 TRIM-STELLITED, STEM SS- RF/125AARH
304

VLV.GLOBE 00.500 01.500 BS- BODY-ASTM A 350 GR.LF2, SW,800, 3000,B-16.11


5352 TRIM-STELLITED, STEM
SS304

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 47 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
VLV.GLOBE 02.000 12.000 BS- BODY-ASTM A 352 GR.LCB, FLGD,300, B16.5, RF/125AARH
1873 TRIM-STELLITED, STEM
SS304

VLV.CHECK 00.500 1.500 BS- BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-16.11
5352 TRIM-STELLITED

VLV.CHECK 02.000 24.000 BS- BODY-ASTM A 352, GR.LCB, FLGD,300, B16.5, RF/125AARH
1868 TRIM-STELLITED

VLV.BALL 00.500 16.000 BS- BODY-ASTM A 352, FLGD,300, B16.5, RF/125AARH


5351 GR.LCB/ ASTM A350,
GR.LF2, TRIM-BODY SEAT-
RPTFE

Bolt Group (B4A)

BOLT.STUD 00.500 14.000 B18.2 BOLT: A 320 GR.L7,


NUT:A194 GR.4

Gasket Group (B4A)

GASKET 00.500 14.000 B16.20- SP,WND, SS316+CAF SPIRAL, 300


ANSI
B16.5

Trap/ Strainer Group (B4A)

STRNR.TEMP 01.500 14.00 GAIL B:A516GR.70(NORM); CONETYPE,300,FF/125AARH


STD.
INT:SS304

STRNR.TEMP 00.500 1.500 GAIL B:A350GR.LF2 SW, Y-TYPE, 800


STD.
(NORM);INT:SS304

STRNR.TEMP 02.000 14.000 M GAIL B:A420GR.WPL6; BW, T-TYPE


STD.
INTR:SS304

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 48 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE G

PIPING MATERIAL SPECIFICATION


(D4A - CLASS 600#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 49 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : D4A, 600 #

BASE MATERIAL : CARBON STEEL

CORROSION ALLOWANCE : 1.5 MM

SPECIAL REQUIREMENT : LOW TEMPERATURE SERVICE

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

SERVICE
NON CORROSIVE PROCESS-FLAMMABLE / NON-FLAMMABLE, NON-LETHAL-BELOW -29DEG C AND
UPTO -45 DEG C.HYDROCARBONS, XYLENE, METHANOL, NH3, GAS FLARE ETC.

NOTES
1. ALL VENTS AND DRAINS SHALL BE PROVIDED WITH GATE VALVE WITH BLIND FLANGE
ASSEMBLY UNLESS OTHERWISE INDICATED IN P&ID.
2. NDT OF WELDS SHALL BE AS FOLLOWS:

RADIOGRAPHY : ALL BUTT WELDS - 100%

MPI : SOCKET WELDS - 100%

3. PIPING DESIGN AS PER ASME B 31.8 & OISD 141 & 226

4. IMPACT TESTING IS REQUIRED

5. 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.

6. FOR VALVES REFER RESPECTIVE VALVE DATA SHEET.

7. FOR DIMENSIONS OF HANDLE PROJECTION FOR SPACER & BLIND, REFER Std. SPEC.
S-05-01-007
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
DRAINS 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
VENTS 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


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.
S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 50 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
70 70
68 68
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60 60
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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 T 18
16 T T 16
14 T T T 14
12 T T T T 12
10 T T T T T 10
8.0 T T T T T T 8.0
6.0 T T T T T T W 6.0
5.0 5.0
4.0 T T T T W W W W 4.0
3.5 3.5
3.0 T T T W W W W W W 3.0
2.5 2.5
2.0 T T T W W W W W W W 2.0
1.5 T T S S S S S S S S S 1.5
1.25 1.25
1.0 T T T S S S S S S S S S 1.0
0.75 T T T T S S S S S S S S S 0.75
0.5 T T T T S S S S S S S S S S 0.5
10.000

12.000

14.000

16.000

18.000
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

RUN PIPE (SIZES IN INCH) – D4A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 51 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)

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 M B 36.10 ASTM A 333 GR.6 PBE,SEAMLESS

NIPPLE 01.000 01.500 M B 36.10 ASTM A 333 GR.6 PBE, SEAMLESS

Flange Group (D4A)

FLNG. SW 00.500 1.50 M B-16.5 ASTM A 350 GR. LF2 600, RF/125 AARH

FLNG. WN 02.000 18.000 M 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 ASME- ASTM A 350 GR. LF2 600, FF/125 AARH
B16.48

SPCR &BLIND 10.000 18.000 ASME- ASTM A 350 GR. LF2 600, FF/125 AARH
B16.48
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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 52 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ELBOW.90 02.000 14.000 M B-16.9 ASTM A 420 GR.WPL6 BW, 1.5D

ELBOW.90 16.000 18.000 M 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 M B-16.9 ASTM A 420 GR.WPL6 BW, 1.5D

ELBOW.45 16.000 18.000 M B-16.9 ASTM A 420 GR.WPL6-W 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 M B-16.9 ASTM A 420 GR.WPL6 BW

T.EQUAL 16.000 18.000 M B-16.9 ASTM A 420 GR.WPL6-W 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, B-16.9 ASTM A 420 GR.WPL6 BW


M

T.RED 16.000 18.000 M, B-16.9 ASTM A 420 GR.WPL6-W BW


M

SWAGE.CONC 00.500 03.000 M,M BS- ASTM A 350 GR.LF2 PBE


3799

SWAGE.ECC 00.500 03.000 M,M BS- ASTM A 350 GR.LF2 PBE


3799

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 M 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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 53 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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 MSS- ASTM A 350 GR.LF2 SW, 6000


SP97

SOCKOLET 01.000 01.500 MSS- ASTM A 350 GR.LF2 SW, 3000


SP97

WELDOLET 02.000 6.000 M, MSS- ASTM A 350 GR.LF2 BW


XXS SP97

Valves Group (D4A)

VLV.GATE 00.500 01.500 API- BODY-ASTM A 350 GR. LF2, SW,800, 3000,B-16.11
602 TRIM-STELLITED, STEM SS-
304

VLV.GLOBE 00.500 01.500 BS- BODY-ASTM A 350 GR.LF2, SW,800, 3000,B-16.11


5352 TRIM-STELLITED, STEM
SS304

VLV.CHECK 00.500 1.500 BS- BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-16.11
5352 TRIM-STELLITED

VLV.PLUG 00.500 1.500 BS- BODY-ASTM A 350, GR.LF2, SW,800, 3000, B-16.11
5353 PLUG:A350 GR.LF2+0.003”
ENP

VLV.PLUG 02.000 18.000 API-6D BODY-ASTM A 352, BW, 600, B-16.25


GR.LCB/ ASTM A350,
GR.LF2, TRIM-SS 304/ SS316

Bolt Group (D4A)

BOLT.STUD 00.500 18.000 B18.2 BOLT: A 320 GR.L7,


NUT:A194 GR.4

Gasket Group (D4A)

GASKET 00.500 18.000 B16.20- SP,WND, SS316+CAF SPIRAL, 600


ANSI
B16.5

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 54 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE H

PIPING MATERIAL SPECIFICATION


(A93A - CLASS 150#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 55 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : A93A, 150 #

BASE MATERIAL : CARBON STEEL

CORROSION ALLOWANCE : 1.5 MM

SPECIAL REQUIREMENT :

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

SERVICE
FIRE WATER (ABOVE GROUND / UNDER GROUND)

NOTES
1. FOR T-TYPE BW STRAINERS, REFER STD. NO.S-05-01-008 & S-05-01-009
2. FORGINGS ARE ACCEPTABLE IN LIEU OF PLATE MATERIAL.
3. SIZES GIVEN IN PMS ARE NOMINAL BORE FOR O.D. OF IS 3589 PIPES REFER ANSI B36.10.

4. 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 FLANGED, TO BE KEPT MINIMUM


PIPE JOINTS 1.5” & BELOW SW COUPLING
2.0” & ABOVE BUTT WELDED
DRAINS 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
VENTS 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-05-01-003.


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.
S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


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40 40
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32 32
30 30
28 28
26 26
24 24
22 22
20 20
18 18
16 16
14 T 14
12 T R 12
10 T R R 10
8.0 T R R R 8.0
6.0 T P R R R 6.0
5.0 5.0
4.0 T R P R R R 4.0
3.5 3.5
3.0 T P R P R R R 3.0
2.5 2.5
2.0 T P P R P R R R 2.0
1.5 T T H H H H H H H 1.5
1.25 1.25
1.0 T T H H H H H H H H 1.0
0.75 T T T H H H H H H H H 0.75
0.5 T T T T H H H H H H H H 0.5
10.000

12.000

14.000
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

8.000

RUN PIPE (SIZES IN INCH) – A93A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 57 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)

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

Flange Group(A93A)

FLNG. SW 00.500 1.50 M B-16.5 ASTM A 105 150, RF/125 AARH

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 ASME- ASTM A 105 150, FF/125 AARH


B16.48

SPCR &BLIND 10.000 14.000 ASME- ASTM A 105 150, FF/125 AARH
B16.48
Fitting Group(A93A)

ELBOW.90 00.500 1.500 B-16.11 ASTM A 105 SW, 3000

ELBOW.90 02.000 6.000 STD B-16.9 ASTM A 234 GR.WPB BW, 1.5D

ELBOW.90 8.000 14.000 M 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 M 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 STD B 16.9 ASTM A 234 GR.WPB BW

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 58 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
T.EQUAL 08.000 14.000 M B-16.9 ASTM A 234 GR.WPB-W BW

T.RED 00.500 01.500 B-16.11 ASTM A 105 SW, 3000

T.RED 02.000 06.000 STD.,STD B-16.9 ASTM A 234 GR.WPB BW

T.RED 08.000 14.000 M, M B-16.9 ASTM A 234 GR.WPB-W BW

REDUC.CONC 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 M 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, TRIM- SW,800, 3000,B-16.11


STELLITED, STEM 13%CR.
STEEL

VLV.GATE 02.000 24.000 API-600 BODY-ASTM A 216 FLGD, 150, B16.5,


GR.WCB, TRIM-13% CR. RF/125AARH
STEEL

VLV.GLOBE 00.500 01.500 BS-5352 BODY-ASTM A 105, TRIM- SW,800, 3000,B-16.11


STELLITED, STEM 13%CR.
STEEL

VLV.GLOBE 02.000 16.000 BS-1873 BODY-ASTM A 216 FLGD, 150, B16.5,


GR.WCB, TRIM-13% CR. RF/125AARH
STEEL

VLV.CHECK 00.500 1.500 BS-5352 BODY-ASTM A 105, TRIM- SW,800, 3000,B-16.11


STELLITED,

VLV.BTRFLY 02.000 24.000 BS-5155 BODY-ASTM A 216 GR. WCB, WAFL, 150, B16.5,
TRIM-13% CR.STEEL, WAF/ 125AARH

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 59 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
Bolt Group(A93A)

BOLT.STUD 00.500 14.000 B18.2 BOLT: A 193 GR.B7,


NUT:A194 GR.2H

Gasket Group(A93A)

GASKET 00.500 14.000 B16.21- IS-2712-GR. W/3 RING, 150, 2MM


ANSI
B16.5

Trap/ Strainer Group(A93A)

STRNR.PERM 00.500 1.500 MNF’STD B:A105;INT;SS304 SW, Y-TYPE, 800

STRNR.PERM 02.000 6.000 M GAIL B:A234GR.WPB;INT:SS304 BW, T-TYPE


STD

STRNR.PERM 08.000 14.000 M GAIL B:A234GR.WPBW;INT:SS304 BW, T-TYPE


STD

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 60 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE I

PIPING MATERIAL SPECIFICATION


(J2A - CLASS 150#)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 61 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
PIPING CLASS : J2A, 150 #

BASE MATERIAL : CS (Galv.)

CORROSION ALLOWANCE : 0 MM

SPECIAL REQUIREMENT :

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

SERVICE
POTABLE WATER (ABOVE GROUND), FIRE WATER-SPRINKLER SYSTEM AFTER ORIFICE

NOTES
1. NDT REQUIREMENTS AS PER GAIL STANDARD – S-05-02-012
2. THREADED JOINTS SHALL BE MADE WITH 1” WIDTH PTFE JOINTING TAPE.
3. SURFACES WHERE GALVANISING HAS BEEN BURNT OFF SHALL BE WIRE BRUSHED AND
COLD GALVANISED WITH ZINC COATING COMPOUND.

SPECIAL NOTES

ITEM 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” REFER GAIL STD. S-05-01-003


ON LINES ≥2.0” AS PER P&ID OR 0.75” REFER STD. S-05-01-004
VENTS 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


TEMP. CONN 1.5” FLANGED, INSTALLATION AS PER GAIL STD. S-05-01-005
PRESS. CONN 0.75” SCREWED NIPPLE WITH VALVE TO SPEC. S-05-01-006

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 62 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
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30 30
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26 26
24 24
22 22
20 20
18 18
16 16
14 14
12 12
10 10
8.0 8.0
6.0 T 6.0
5.0 5.0
4.0 T T 4.0
3.5 3.5
3.0 T T T 3.0
2.5 2.5
2.0 T T T T 2.0
1.5 T T T T T 1.5
1.25 1.25
1.0 T T T T T T 1.0
0.75 T T T T T T T 0.75
0.5 T T T T T T T T 0.5
0.500
0.500
0.750

1.000

1.250

1.500

2.000

2.500

3.000

3.500

4.000

5.000

6.000

RUN PIPE (SIZES IN INCH) – J2A

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 63 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
CODE DESCRIPTION
F SADDLE FUSED JT T TEES
H H.COUPLING W WELDOLETS
P PIPE TO PIPE I INSTRUMENT TEE
R REINFORCED X REFER NOTES
S SOCKOLETS L SWEEPOLET
Lower Upper
Sch./ Dim.
Item Type Size Size Material Description
Thk STD
(Inch) (Inch)

Pipe Group (J2A)

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

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 ASME- ASTM A 105 (GALV.) 150, FF/125 AARH
B16.48

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

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 64 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
UNION 00.500 06.000 IS-1239-II IS-1239 (PART-II) (GALV.) SCRF, NA

Valves Group(J2A)

VLV.GATE 00.500 01.500 IS:778 BODY-IS 318 GR.2 LEADED SCRF, CL.2, 3000, B-
CL.2 TIN BRONZE, TRIM-IS320 1.20.1
ALLOY HT2

VLV.GATE 02.000 6.000 IS:780 BODY-IS 210,GR.FG 200, FLGD, PN 1.6, B


TRIM-IS 320 ALLOY HT2 16.1,FF/125AARH

VLV.GLOBE 00.500 01.500 IS:778 BODY-IS 318 GR.2 LEADED SCRF, CL.2, 3000, B-
CL.2 TIN BRONZE, TRIM-IS320 1.20.1
ALLOY HT2

VLV.CHECK 00.500 1.500 IS:778 BODY-IS 318 GR.2 LEADED SCRF, CL.2, 3000, B-
CL.2 TIN BRONZE, TRIM-IS320 1.20.1
ALLOY HT2

VLV.CHECK 02.000 6.000 IS:5312 BODY-IS 210 GR.FG 200, FLGD, PN1.6, B-16.1,
(PT-1) TRIM-IS 320 ALLOY HT2 FF/125AARH

Bolt Group(J2A)

BOLT.M/C 00.500 6.000 B18.2 BOLT: A 307, GR.B (GALV),


NUT:A563 GR.B (GALV)

Gasket Group(J2A)

GASKET 00.500 6.000 B16.21- BUTYL RUBBER FULL FACE, 150, 2MM
ANSI
B16.5

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 65 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
ANNEXURE-I

LIST OF ATTACHMENTS

Sl. DOCUMENT DOCUMENT REV


No. NO. .
1 Jack Screw for Spectacle Blind (150#, 300#, S-05-01-001 0
600#)
2 Jack Screw for Spacer and Blind (150#, S-05-01-002 0
300#, 600#)
3 Vents & Drains on lines (On lines 1- ½ “ & S-05-01-003 0
Below)
4 Vents & Drains on lines (On lines 2 “ & S-05-01-004 0
above)
5 Wells Installation 1- ½ “ Dia Taps S-05-01-005 0
6 Pressure Tappings – PG, PT, PI, PA, PC etc S-05-01-006 0
7 Dimn. For Handle Projections for Spacers S-05-01-007 0
and Blinds
8 T-Strainer Type-1 2"-4" (150# RF, 300# S-05-01-008 0
RF and RTJ, 600# RF and RTJ)
9 T-Strainer Type-1 6"-24" (150# RF, 300# S-05-01-009 0
RF and RTJ, 600# RF and RTJ)
10 Standard Specification of LSAW pipe S-04-02-001 0
11 Standard Specification of HSAW pipe S-04-02-002 0
12 Standard Specification for Long Radius S-04-02-015 0
Bends for onshore Pipelines
13 Specification for Insulating Joints for S-04-02-019 0
Onshore Pipelines
14 Standard Specification for Seamless fittings S-04-02-013 0
& Flanges, Size up to DN 400 mm (16”)
15 Specification for flanges & Welded Fittings S-04-02-014 0
(Size DN 450 mm (18") and above
16 Specification for Seamless fittings & S-04-02-013 0
Flanges, Size up to DN 400 mm (16”)
17 Technical Notes for Valves S-05-02-002 0
18 Technical Notes for Pipes S-05-02-001 0
19 Technical Notes for Butt Welded, Socket S-05-02-003 0
Welded and Screwed Fittings
20 Technical Notes for Flanges, Spectacle S-05-02-004 0
Blinds and Drip Rings
21 Technical Notes for Bolts and Nuts S-05-02-005 0
22 Technical Notes for Gaskets S-05-02-006 0
23 Inspection and Test Plan for Gaskets S-14-06-001 0
24 Specification for Shop and Field Painting S-05-02-014 0
25 Standard Specification for Fabrication and S-05-02-011 0
Erection of Piping
26 Standard specification for Inspection, S-05-02-013 0
Flushing and Testing of Piping system
27 Standard Specification of “Non-Destructive S-05-02-012 0
Examination of Piping”
PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0
GAIL (INDIA) LTD (PHASE –II) Page 66 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
28 Standard Specification for Quick Opening S-04-02-024 0
End Closure
29 Standard Specification of Plug Valve S-04-02-008 0
30 Standard Specification of Ball Valve S-04-02-007 0
31 Standard Specification for Positive Material S-14-02-001 0
Identification at Vendor’s Works.

LIST OF DATASHEETS

Sl. TITLE DATA SHEET NO. RE


No. V.
1 Data Sheet for Insulating Joints 0001-01-04-04-IJ-005 & 006 0
2 Data Sheet for Ball Valve 0001-01-05-04-BV-004 0
3 Data Sheet for Plug Valve 0001-01-04-04-PV-001 & 0
002
5 Data Sheets for Gate Valves of Size 0001-01-05-04-GV-001 0
below 2”

TABLE-3
PIPELINE SPECIALITY ITEMS
MAINLINE (FROM CGS TO CUSTOMER METERING STATION)
Sl. No. ITEM MATERIAL DESCRIPTION
1 INSULATING JOINTS Monoblock type
8” - API 5L Gr. X 56, PSL-2 / ASTM A694 Gr. F56
(CHARPY)
4” - API 5L Gr. X 42, PSL-2 / ASTM A694 Gr. F42
(CHARPY)

PIPING MATERIAL SPECIFICATION SPECIFICATION REV-0


GAIL (INDIA) LTD (PHASE –II) Page 67 of 67
NEW DELHI 0001-01-05-02-001-Phase –II
WELDING SPECIFICATION FOR MAIN LINE
FOR
TRANSPORTATION OF GAS

SPUR LINE CHAINSA – JHAJJAR PIPELINE


(PHASE-II)

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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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: 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

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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 tapings.

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) Welding and Brazing Qualifications, ASME Sec. IX

3.0 BASE MATERIAL

In general carbon steel is used in this specification. The details of material


specifications are given in the welding Specification Chart attached along with other
project data sheets. The CONTRACTOR shall arrange and maintain the record of
test certificates of all the materials for the reference of the welding engineer.

4.0 WELDING CONSUMABLES


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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.

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 be 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
GTAW process shall bear the approval of the COMPANY. 99.995% pure Argon
shall be used. Moisture content shall correspond to a dew point of -300C or
lower.

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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 8ӯ Industrial distribution networks and 4ӯ individual customer connectivity Lines
by SMAW Process for all the passes. Non-destructive examination shall be carried
out as per requirements of section 12.5.

6.1.2 Welding procedure 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.

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

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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 beveled-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-beveled with an approved beveling 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 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. 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
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.
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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, if used, 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
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.

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d) Any deviations from the recommended welding techniques and welding
consumables indicated in the welding specification chart shall be permitted only
after obtaining written approval of the COMPANY.

e) Welding shall be continuous and uninterrupted during a pass.

f) On completion of each run, craters, welding irregularities, slag etc. shall be


removed by grinding and chiseling.

g) While the welding is in progress, proper care shall be taken to avoid any kind of
movement of the components, shocks, vibration and stresses to prevent
occurrence of weld cracks.

h) Fillet weld shall be made by Shielded Metal Arc Welding (SMAW) process,
irrespective of the thickness and class of piping. SMAW electrode size shall not
exceed 3.25 mm diameter for the socket joint. At least two passes shall be
made on the socket weld joint.

i) Peening shall not be used.

10.2 Joint Completion

The first pass shall be carried out in such a manner that distortion in the pipe is
minimum.

The number of welders / welding heads and the allowable welding sequences shall
be same 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.

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.
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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.

12.0 INSPECTION AND TESTING

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.

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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) To check the conformance to relevant standards and suitability of various


welding equipment and the welding performance.

ii) To supervise the welding procedure qualification.

iii) To supervise the welders’ performance qualification.

iv) 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) COMPANY’S 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
COMPANY’S 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 Company’s Inspector. The
destructive testing of welded joints shall be as per Annexure -1.

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
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nondestructive examination requirements specified in Clause 12.5 and
Annexure- 2 & 3 (as applicable) of this specification. The Company’s
Inspector shall witness the test and certify the qualification of each welder
separately. Only those welders who have been approved by the Company’s
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 Company’s
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.

In addition to Radiography requirement as per clause 12.5.2, Radiography


examination shall be carried out in the following cases as per Annexure-3 of this
specification:

a) When welds are repaired.

b) When in the opinion of COMPANY, Radiography Testing is required to


confirm or clarify defects indicated by Ultrasonic Testing.

c) 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’s discretion. All fillet and groove welds shall be subjected to Dye-
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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 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) When welds are repaired.

b) 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.

12.5.4 Acceptance Criteria

Weld quality is judged on the basis of the acceptability criteria mentioned below:

i) Any weld, which as a result of Radiography and/or Ultrasonic examination in


the opinion of COMPANY exhibits imperfections greater than the limits stated
in API 1104 latest edition or as superseded in this specification, shall be
considered defective and shall so be marked with an identification point
marker.

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

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shall present the records to the COMPANY on day-to-day basis and whenever
demanded, for approval.

12.6 Destructive Testing

Welds cut out for defects or for other reason may be subjected to destructive
testing. The re-execution of welds shall be carried out by the CONTRACTOR at his
own expense. If the results are unsatisfactory, the welding operations shall be
suspended and may not be restarted, until the causes have been identified and the
suitable measures that guarantee acceptable results have been adopted by the
CONTRACTOR. If it is necessary in the Company’s 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 API-
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.

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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 DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS

1.1 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 25x. 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 V-
Notch 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, latest edition. The dimensions of the Jig for guided bend test in Figure.9 of
API 1104 shall be modified as specified below:

Radius of the Plunger `A' = 2t

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Radius of the die. `B' = 3t + 1.6 mm

Width of the die. `C' = 50.8

Where t = thickness of the specimen

The acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API
1104 Nineteenth edition, September 1999.

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ANNEXURE – 2 (ULTRASONIC TESTING)

1.0 ULTRASONIC TESTING

In addition to the Radiography testing, Ultrasonic testing is required as per


conditions listed in paragraph 12.5 of this specification. This section concerns
manual Ultrasonic inspection. However Ultrasonic inspection by automatic
equipment may be used if approved by the COMPANY.

1.1 GENERAL:

The CONTRACTOR who carries out the Ultrasonic inspections shall have sufficient
no. of qualified personnel, equipment and instruments at his disposal to be carried
out the tests without hindering or delaying the pipeline assembly operations.

The CONTRACTOR appointed shall supply all the requisite instruments to carry out
Ultrasonic inspection at site.

1.2 SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE

The CONTRACTOR shall present a Specification describing the proposed Ultrasonic


testing procedure qualification.

This specification shall state the following information including all the parameters
described in API 1104:

a) 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.

1.3 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
Company’s 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. 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 weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference
amplifications and the probe shall be moved until maximum response is
obtained, paying attention all the 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 be
examined.

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ANNEXURE-3 (RADIOGRAPHY TESTING)
1.0 SCOPE

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

vi) 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.
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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.

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.

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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.

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
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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
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.

1.0 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.
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9.4 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.

10.0 QUALIFICATION OF RADIOGRAPHERS

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.

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13.0 RADIATION PROTECTION

13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
every man with or near radiation sources.

13.2 The protection and monitoring shall comply with local regulations.

13.3 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
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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EXHIBIT - A
Sheet 1 of 3

ELECTRODE QUALIFICATION TEST RECORD

A: 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) :

B: 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. U.T.S Yield Point Elongation Remarks

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EXHIBIT - A
Sheet 2 of 3

C: Impact Test Results

Test Temperature: Notch in:

Type of Specimens (Charpy): Size of Specimens:

Specimen No. Impact Value Average

1
2
3

D: Chemical Analysis Results

Electrode Size Result :

Batch No. :

%C %S %P % Si % Mn % Cr % Ni % Mo OTHER

E: Fillet Weld Test Results :

Welding Positions :

Base Materials :

Size of electrode use :

Visual Inspection Results :

1)

2)

3)

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EXHIBIT - A
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 :

IDENTIFICATION ROOT, FACE OR


POSITION REMARKS
NO. SIDE BEND
1
2
3

G. Any other tests :

H. Conclusions :

--------------- ----------------- ----------------


PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER)

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


GAIL (INDIA) LTD MAIN LINE FOR TRANSPORTATION Page 33 of 46
NEW DELHI OF GAS 0001-01-04-02-001(II)
Copyright GAIL – All rights reserved
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 Type of heating: Gas / Oil / Elec.


equipment:________ (Tick mark applicable method)

Name of the Assembly/Part : Res./Induction Type of Heating :

Drawing No.: Capacity (Size):

Material: Maximum Temp.( °C):

Method of temp. Measurement:

Atmosphere Control:

2. Heat Treatment Cycle Details

Charging Temp (0C) __________________________________

Rate of heating (0C/Hr.)_______________________________

Soaking Temperature (0C)_______________________________

Soaking Time (Hrs.) ___________________________________

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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EXHIBIT – B
Sheet 2 of 2

Rate of cooling (0C/Hr.)_______________________________

Method of Cooling_____________________________________

3. 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 REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER)

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


GAIL (INDIA) LTD MAIN LINE FOR TRANSPORTATION Page 35 of 46
NEW DELHI OF GAS 0001-01-04-02-001(II)
Copyright GAIL – All rights reserved
EXHIBIT – C
Sheet 1 of 3

FORM FOR WELDING PROCEDURE QUALIFICATION TEST RECORD

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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EXHIBIT – C
Sheet 2 of 3

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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EXHIBIT – C
Sheet 3 of 3

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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EXHIBIT – D
Sheet 1 of 1
FORM FOR WELDER QUALIFICATION TEST RECORD

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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NEW DELHI OF GAS 0001-01-04-02-001(II)
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EXHIBIT – E
Sheet 1 of 1
WELDER’S IDENTITY CARD

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


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NEW DELHI OF GAS 0001-01-04-02-001(II)
Copyright GAIL – All rights reserved
EXHIBIT – F
Sheet 1 of 1
RADIOGRAPHIC PROCEDURE FOR PIPE WELDING

WELDING SPECIFICATION FOR SPECIFICATION REV- 0


GAIL (INDIA) LTD MAIN LINE FOR TRANSPORTATION Page 41 of 46
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WELDING SPECIFICATION FOR SPECIFICATION REV- 0
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WELDING SPECIFICATION FOR SPECIFICATION REV- 0
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WELDING SPECIFICATION FOR SPECIFICATION REV- 0
GAIL (INDIA) LTD MAIN LINE FOR TRANSPORTATION Page 46 of 46
NEW DELHI OF GAS 0001-01-04-02-001(II)
Copyright GAIL – All rights reserved
PIPING CLASS: MAIN PIPELINE (8” & 4”)

MATERIAL PIPES API 5L Gr. X-56 (PSL-2), API 5L Gr. X-42 (PSL-2)
SPECIFICATION FITTINGS -
FLANGES -
OTHERS -

BASE METAL “P” NO. 1


GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING ROOT PASS: FILLER PASS: ROOT PASS: FILLER PASS:
PROCESS SMAW SMAW SMAW SMAW
FILLET JOINTS / SOCKET JOINTS: SMAW

GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING ROOT PASS: FILLER PASS: ROOT PASS: FILLER PASS:
MATERIAL E 6010 E 7010 E 6010 E 7010
FILLET JOINTS / SOCKET JOINTS: E 7010
BACKING RING: - CONSUMABLE INSERT: -

JOINT ASME B 31.8 & OISD 141


PREPARATION

GASES PURGING SHIELDING: ARGON


GAS PURGING SHIELDING: 99.995%
COMPOSITION
PRE-HEATING PRE-HEAT TEMP.: 1000C POST HEATING:
CONTINUTY OF WELDING AND PREHEAT: REFER GAIL STANDARD S-04-02-034
POST WELD HOLDING TEMP: HOLDING TIME:
HEAT RATE OF HEATING: MIN. HOLDING TIME:
TREATMENT METHOD OF COOLING: RATE OF COOLING:

MECHANICAL CHARPY ‘V’ NOTCH IMPACT TEST MIN.: 22 J


PROPERTY VALUE: AVERAGE: 27 J
REQUIREMENTS AT TEMPERATURE: 00C
HARDNESS:

CODE OF ASME 31.8


FABRICATION

WELDING SPECIFICATION CHARTS FOR SPECIFICATION REV-1


GAIL (INDIA) LTD PIPE WELDING
NEW DELHI 0001-01-04-02-001-WSC1(II) Page 1 of 2
Copyright GAIL – All rights reserved
PIPING CLASS: A1A, B1A, D1A

MATERIAL PIPES ASTM A106 GRB, API 5L GRB (PSL-2), API 5L GR. X-70
SPECIFICATION (PSL-2), API 5L GR. X-65 (PSL-2), API 5L GR. X-60 (PSL-
2), API 5L GR.X-56 (PSL-2)
FITTINGS ASTM A-105, ASTM A234 GR. WPB, ASTM A234 GR.
WPB-W, MSS-SP-75 GR.WPHY70/65/60/56/52
FLANGES ASTM A105, ASTM A 694 GR. F-52/65/70
OTHERS -

BASE METAL “P” NO. 1


GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING ROOT PASS: FILLER PASS: ROOT PASS: FILLER PASS:
PROCESS GTAW GTAW / SMAW GTAW GTAW / SMAW
FILLET JOINTS / SOCKET JOINTS: SMAW

GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING ROOT PASS: FILLER PASS: ROOT PASS: FILLER PASS:
MATERIAL ER 70 S-2 ER 70 S-2 / ER 70 S-2 ER 70 S-2 / E
E7018-1 7018-1
FILLET JOINTS / SOCKET JOINTS: E 7018-1
BACKING RING: - CONSUMABLE INSERT: -

JOINT ASME B 31.8 & OISD 141


PREPARATION

GASES PURGING SHIELDING: ARGON


GAS PURGING SHIELDING: 99.995%
COMPOSITION
PRE-HEATING PRE-HEAT TEMP.: 1000C POST HEATING:
CONTINUTY OF WELDING AND PREHEAT: REFER GAIL STANDARD S-04-02-034
POST WELD HOLDING TEMP: HOLDING TIME:
HEAT RATE OF HEATING: MIN. HOLDING TIME:
TREATMENT METHOD OF COOLING: RATE OF COOLING:

MECHANICAL CHARPY ‘V’ NOTCH IMPACT TEST MIN.: 27 J


PROPERTY VALUE: AVERAGE: 36 J
REQUIREMENTS AT TEMPERATURE: 00C
HARDNESS:

CODE OF ASME 31.8


FABRICATION
Note:

1. Heat treatment shall be done as per ASME B 31.3 for wall thickness exceeding 19mm.
2. Pre-heat temperature of at least 500C shall be provided for the first two passes for thickness ≥ 12.7mm
and < 25.4 mm.

WELDING SPECIFICATION CHARTS FOR SPECIFICATION REV-1


GAIL (INDIA) LTD PIPE WELDING
NEW DELHI 0001-01-04-02-001-WSC1(II) Page 2 of 2
Copyright GAIL – All rights reserved
PIPING CLASS: A4A, B4A, D4A

MATERIAL PIPES ASTM A333 GR. 6


SPECIFICATION FITTINGS ASTM A350 GR. LF-2, ASTM A420 GR. WPL6,
ASTM A420 GR. WPL6-W
FLANGES ASTM A350 GR. LF-2
OTHERS -

BASE METAL “P” NO. 1


GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING ROOT PASS: FILLER PASS: ROOT PASS: FILLER PASS:
PROCESS GTAW GTAW / SMAW GTAW GTAW / SMAW
FILLET JOINTS / SOCKET JOINTS: GTAW / SMAW

GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING ROOT PASS: FILLER PASS: ROOT PASS: FILLER PASS:
MATERIAL ER 70SG ER 70SG WIRE / ER 70 SG ER 70SG WIRE /
E7018-1 E 7018-1
FILLET JOINTS / SOCKET JOINTS: E 7018-1
BACKING RING: - CONSUMABLE INSERT: -

JOINT ASME B 31.8 & OISD 141


PREPARATION

GASES PURGING SHIELDING: ARGON


GAS PURGING SHIELDING: 99.995%
COMPOSITION
PRE-HEATING PRE-HEAT TEMP.: 100C min, 1000C POST HEATING:
for thk ≥25.4mm
CONTINUTY OF WELDING AND PREHEAT: REFER GAIL STANDARD S-04-02-034
POST WELD HOLDING TEMP: HOLDING TIME:
HEAT RATE OF HEATING: MIN. HOLDING TIME:
TREATMENT METHOD OF COOLING: RATE OF COOLING:

MECHANICAL CHARPY ‘V’ NOTCH IMPACT TEST MIN.: 21 J


PROPERTY VALUE: AVERAGE: 27 J
REQUIREMENTS AT TEMPERATURE: At -46.50C OR DESIGN TEMP.
WHICHEVER IS HIGHER
HARDNESS:

CODE OF ASME 31.8


FABRICATION
Note:

1. ER 70-SG wire shall be impacted at -46.50C or design temperature whichever is higher.


2. Heat treatment shall be done as per ASME 31.8 for wall thickness exceeding 19mm.

WELDING SPECIFICATION CHARTS FOR SPECIFICATION REV-0


GAIL (INDIA) LTD PIPE WELDING- A4A, B4A & D4A
NEW DELHI 0001-01-04-02-001-WSC2(II) Page 1 of 1
Copyright GAIL – All rights reserved
JOB SPECIFICATION FOR
GEOTEXTILE BAGS
FOR ANTI-BUOYANCY

SPUR LINES OF CHAINSA-JHAJJAR PIPELINE


(PHASE-II)

SPECIFICATION FOR GEOTEXTILE BAGS SPECIFICATION REV-0


GAIL (INDIA) LTD FOR ANTI-BUOYANCY
NEW DELHI 0001-01-04-02-002 (II) Page 1 of 6
Copyright GAIL – All rights reserved
TABLE OF CONTENTS

1.0 SCOPE

2.0 DESIGN

3.0 MATERIAL

4.0 DELIVERY, STORAGE, HANDLING

5.0 MARKING

6.0 OTHER TECHNICAL REQUIREMENTS

7.0 INSTALLATION

9.0 DOCUMENTATION

SPECIFICATION FOR GEOTEXTILE BAGS SPECIFICATION REV-0


GAIL (INDIA) LTD FOR ANTI-BUOYANCY
NEW DELHI 0001-01-04-02-002 (II) Page 2 of 6
Copyright GAIL – All rights reserved
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 8” &
4” 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


manufacturer.

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 5.0 meters for 8” & 4” pipelines.

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
3.1 The body fabric must be treated for UV protection and longevity. The weight of the
SPECIFICATION FOR GEOTEXTILE BAGS SPECIFICATION REV-0
GAIL (INDIA) LTD FOR ANTI-BUOYANCY
NEW DELHI 0001-01-04-02-002 (II) Page 3 of 6
Copyright GAIL – All rights reserved
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. Product model

b. 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

SPECIFICATION FOR GEOTEXTILE BAGS SPECIFICATION REV-0


GAIL (INDIA) LTD FOR ANTI-BUOYANCY
NEW DELHI 0001-01-04-02-002 (II) Page 4 of 6
Copyright GAIL – All rights reserved
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 8” & 4”, 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.

8.5 Complete descriptive technical catalogues describing the materials offered along with
SPECIFICATION FOR GEOTEXTILE BAGS SPECIFICATION REV-0
GAIL (INDIA) LTD FOR ANTI-BUOYANCY
NEW DELHI 0001-01-04-02-002 (II) Page 5 of 6
Copyright GAIL – All rights reserved
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.

SPECIFICATION FOR GEOTEXTILE BAGS SPECIFICATION REV-0


GAIL (INDIA) LTD FOR ANTI-BUOYANCY
NEW DELHI 0001-01-04-02-002 (II) Page 6 of 6
Copyright GAIL – All rights reserved
TECHNICAL SPECIFICATION
FOR
PRECOMMISSIONING AND
COMMISSIONING

SPUR LINES OF CHAINSA-JHAJJAR PIPELINE


(PHASE-II)

TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0


GAIL (INDIA) LTD PRECOMMISSIONING AND
NEW DELHI COMMISSIONING 0001-01-04-02-003 (II) Page 1 of 15
Copyright GAIL – All rights reserved
TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 RESPONSIBILITY OF
CONTRACTOR

3.0 SCOPE OF WORK

3.1 Pre-Commissioning activities

3.2 Commissioning related activities

4.0 DOCUMENTATION

5.0 SPARES AND COMSUMABLES

6.0 SAFETY

TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0


GAIL (INDIA) LTD PRECOMMISSIONING AND
NEW DELHI COMMISSIONING 0001-01-04-02-003 (II) Page 2 of 15
Copyright GAIL – All rights reserved
1.0 INTRODUCTION
This specification covers the minimum technical requirements for:

i.) Pre-commissioning of :

Sl. Pipeline Tap-off Point Size(Inch) X


Length (Km)

1 Dharuhera D/S of Dharuhera CGS 8”X 5.25 km


Distribution
network
Dharuhera 8” Distribution network 4” x 1.7 km
Customer
end
connectivity
2 Bhiwadi D/S of Bhiwadi CGS 4” X 1.2 km
Distribution
network
Customer
end
connectivity
3 Khushkhera D/S of Khushkhera CGS 8”X 2.25 km
Distribution
network
Khushkhera 8” Distribution network 4” x 2.9 km
Customer
end
connectivity
4 Neemrana D/S of Neemrana CGS 8”X 3.25 km
Distribution
network
Neemrana 8” Distribution network 4” X0.06 km
Customer
end
connectivity
5 Manesar D/S of Manesar CGS 8” X 8.3 km
Distribution
network
5 Manesar 8” Distribution network 4” x 1.6 km
Customer

TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0


GAIL (INDIA) LTD PRECOMMISSIONING AND
NEW DELHI COMMISSIONING 0001-01-04-02-003 (II) Page 3 of 15
Copyright GAIL – All rights reserved
end
connectivity
6 Gurgaon D/S of Gurgaon 8” X 7.8 km
Distribution Terminal station at Hero
network Honda
Gurgaon From 10” Hayatpur – 4” x 4.1 km
Customer Gurgaon Line (for M/s.
end Heema Engg. & M/s.
connectivity Neel metals) & from 8”
Distribution network (for
other customers)

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 bidder’s 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
absence of this, it shall be considered that the bidder has no deviation.

 Questionnaire as given in Appendix-I duly filled by bidder.

2.0 RESPONSIBILITY OF CONTRACTOR


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

2.1 Pre-commissioning

In order to execute and perform pre-commissioning activities, the contractor shall


be responsible for (but not limited to):
TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0
GAIL (INDIA) LTD PRECOMMISSIONING AND
NEW DELHI COMMISSIONING 0001-01-04-02-003 (II) Page 4 of 15
Copyright GAIL – All rights reserved
• Carrying out pre-commissioning checks of the underground pipeline system
including above ground piping at CGS / Terminal station and at Customer
metering stations, tap-off / hook-up piping etc.

 Dewatering of the pipeline.

 Flushing and dry air blowing of under ground & above ground piping at all
stations and hook–up points.

 Swabbing of pipeline.

 Low pressure leak check (with air) for the aboveground section of the pipelines.

 Supply and supervision of manpower for pre-commissioning.

 Supply and operation of machinery & equipment for pre-commissioning.

 Supply and use of materials and consumables as required for the pre-
commissioning activities.

 Design and supply all temporary line connections, valves, instruments,


manpower etc. as required during various operations.

 Preparation of detailed pre-commissioning 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
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 Company’s 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
TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0
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NEW DELHI COMMISSIONING 0001-01-04-02-003 (II) Page 5 of 15
Copyright GAIL – All rights reserved
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 all stations
and hook-up / tap-off points to a water dew point of 0°C 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 all stations and hook-up / tap-off points.

 Inertisation of the pipeline system including above ground piping system at all
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 all
and hook-up points.

 Stabilization and 72 hours run of the pipeline system.

 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, 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.

TECHNICAL SPECIFICATION FOR SPECIFICATION REV-0


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NEW DELHI COMMISSIONING 0001-01-04-02-003 (II) Page 6 of 15
Copyright GAIL – All rights reserved
 All necessary work to perform the job successfully including all modifications that
would be required.

 The contractor shall demonstrate to the COMPANY (for Company’s approval) the
successful completion of all of the abovementioned activities.

 In the event of any detail, which is not fully addressed, contractor should warrant
that work shall be performed in accordance with the relevant codes, Company's
specifications and the best recognized Engineering guidelines and practices being
followed in the on-shore pipeline industry.

3.0 SCOPE OF WORK


The work to be performed by the Contractor as part of the pre-commissioning
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 Pre-commissioning activities

3.1.1 Pre-commissioning checks

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, all
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 short comings
observed shall be listed down in the form of punch lists and duly attended.

B) Checking of Field Instruments

All the field instruments like actuated valves, transmitters, 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

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This shall be performed to confirm that proper fittings/supports, Cathodic
protection system, route markers, warning signs, fencing around 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.

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.

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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 pipeline’s 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.

Contractor may suggest alternate methodology for de-watering operation.

Flushing of aboveground piping

Flushing of above ground piping at all stations and hook-up / tap-off points 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.

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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 Company’s approval.

3.2 Commissioning related activities

3.2.1 Drying

3.2.1.1 General

The pipeline system including the underground pipeline and the above ground
piping at all 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 pre-commissioning activities. The pipeline
shall be dried by using super dry air / vacuum method or by any other suitable
method.

Contractor shall submit the detailed procedure and the duration of the drying
operation and obtain Company's approval on the same prior to start of the drying
operation.

Commissioning contractor shall assess any requirement of swabbing for entire


pipeline to reduce the time for drying and shall carryout such activity.

3.2.1.2 Acceptance criteria

Contractor shall ensure that drying operation is complete before proceeding to the
next step of inertisation. The drying of the pipeline system shall be considered to
be achieved on attaining a water dew point of 0°C 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


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3.2.2.1 General

The aboveground piping sections of the pipeline system shall be checked for leaks
at flange points of piping and equipment, instrument impulse tubing points etc.
This shall be done by pressurizing the system piping / equipment with dry
compressed air (for this purpose, oil free air compressors shall be used) and
testing the system by means of soap solution for leaks.

The contractor shall submit the detailed procedure and the duration of the leak
check operations and obtain approval of the company before starting the
operation.

3.2.2.2 Acceptance criteria

The leak check operation shall be considered to be completed when the piping
system / equipment is free of leaks when tested at a pressure of 6.0 Kg/cm2g. This
shall be subject to Company’s 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 all 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 all stations and hook-up /
tap-of points.

3.2.4.2 Operational requirements

During the Inertisation operation, the dry air left in all the pipeline shall be
replaced by dry nitrogen before admitting the natural gas into the pipeline for safe
commissioning. Depending on the commissioning plan / strategy, sections of the
pipeline system may be taken up for commissioning in steps. One of the suggested
methods for Inertisation of the underground pipeline is by the usage of nitrogen
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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 totalized 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.

For above ground piping at all 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 pipelines 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 all stations and hook-up / tap-of 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 all 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.

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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 all
stations and hook-up / tap-of points.

3.2.6.2 Operational requirements

During introduction of natural gas into the pipeline, natural gas shall be the motive
fluid for driving the last pig of the nitrogen slug train. The pig train speed shall be
maintained at 3 to 4 Km/hr. Maintenance of proper backpressure shall control pig
train speed. Venting shall be controlled at the pig-receiving end to achieve the
desired dynamics. In this fashion, slowly the desired portion of the pipeline shall
be commissioned. Alternatively contractor may propose procedure for introduction
of gas in pipeline under vacuum condition after inertisation with Nitrogen.

Subsequently, the pipeline system shall be slowly pressurized up to 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 / Company’s 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 all
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.
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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
• 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 pre-commissioning and commissioning formats and check sheets.

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 pre-
commissioning 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
NOT
}CLAUSE DESCRIPTION OF CLAUSE AGREED REMARKS
AGREED
NO.

1.0 SCOPE [ ] [ ]
2.0 DEFINITIONS [ ] [ ]

3.0 MANUFACTURER REPRESENTATIVE [ ] [ ]

DOCUMENT FOR PRECOMMISSIONING


4.0 [ ] [ ]
AND COMMISSIONING

5.0 OTHER REQUIREMENTS [ ] [ ]


REVIEW/CHECKLISTING/INSPECTION/CO-
6.0 [ ] [ ]
ORDINATION
7.0 COMMISSIONING [ ] [ ]
8.0 CONSUMABLES [ ] [ ]
9.0 SPECIAL REQUIREMENTS [ ] [ ]
10.0 SAFETY [ ] [ ]

NOTE: 1) PLEASE TICK THE RELEVANT BOX.


2) 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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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
2 REFERENCES
5 PROCESS OF MANUFACTURE AND MATERIAL
6 MATERIAL REQUIREMENTS
7 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES
9 INSPECTION AND TESTING
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 4½ 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 : Boiler & Pressure Vessel code: Welding & brazing quality.
ASME B31.8 : Gas Transmission & Distribution piping system.
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OISD – 141 : Oil Industries safety distribution piping system
API RP 5 L1 : 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:
Welding Process : Submerged Arc Welding as per para 5.1.2.2.1
Type of Pipe : Longitudinal Seam Submerged Arc Welded Pipe as
per para 5.1.3.5
Type of Seam Weld : Submerged Arc Weld (Longitudinal Seam) as per
para 5.1.4.3

5.2 COLD EXPANSION


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

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

5.4 HEAT TREATMENT


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

6.0 Material Requirements


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 )
C 0.16 max.
Mn 1.50 max. (For Grade B to X52)
1.60 max. (For Grade X56 to X70)
Si 0.15 min.
0.45 max.
S 0.015 max.
P 0.02 max.
Al 0.07 max.
Nb 0.05 max.
V 0.08 max.
Ti 0.04 max. (For Grade B toX60)
0.06 max. (For Grade X65 to X70)
Cr 0.20 max.
Mo 0.10 max.
Cu 0.35 max.
Ni 0.20 max.
N 0.012 max.
B 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:
CE (Pcm ) ‫ﮐ‬ 0.20 %
CE (IIW ) ‫ﮐ‬ 0.40 %

6.2 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 Permissible in excess of SMYS. Psi (MPa)
Up to and including X46 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
least 3 times per operating shift (12 hours maximum).
Checking of the weld seam misalignment shall also be carried out on metallographic
examination specimen as stated at para 6.2.6,
7.8.4 Height of Outside and Inside Weld Beads - Submerged Arc Welds
The maximum height of outside and inside weld bead shall not be more than 3.2 mm (1/8 in.)
for all specified wall thickness. All pipes shall be checked for weld bead height using a
template having a cut out for weld bead and shall be measured and recorded at least 3 times
per operating shift (12 hours maximum).

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7.8.8 Hard Spots
Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any direction and
hardness greater than 248 HV10 shall be rejected. The section of pipe containing the hard spot
shall be removed as a cylinder.
7.8.9 Cracks, Sweats and Leaks
Sections of the pipe containing cracks, sweats and leaks shall be cut off as per the
requirement of API Spec 5L para 9.9 (c) or (d).
7.8.10 Laminations
Any lamination or inclusion either extending into the face or bevel of the pipe or present within
25 mm from pipe ends is considered defect and pipe containing such defects shall be cut back
until such defects are eliminated.
The acceptance limit and disposition of lamination and other type of detects on the plate/skelp
shall be as per para 9.8.5.4 of this specification.
7.8.12 Undercuts
Undercutting not classified as minor shall be considered a defect. Disposition shall he
as follows:
1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding 12 ½ % 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 ½ % 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 12¾”, 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 Fracture Toughness Tests


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 purchaser’s 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
/ OWNER’S representative during manufacturing. Minimum Burst Test pressure shall not be
less than the actual tensile stress factor computed pressure.

9.5 DIMENSIONAL TESTING


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

9.7 VISUAL INSPECTION


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

9.8 NON DESTRUCTIVE INSPECTION


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

ii.For all other NDT methods


Evaluation of indications : 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 x½ t depth, where ‘t’ is the specified wall thickness.
The reference standard for plate/skelp edge UT and pipe ends shall have ¼ 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
REPAIR OF DEFECTS BY WELDING (NORMATIVE)
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
REPAIR WELDING PROCEDURE (NORMATIVE)
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
SUPPLEMENTARY REQUIREMENTS (NORMATIVE)
SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 ½ 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
+32°F (0°C). 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 +32°F (0°C).
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 32°F (0°C) or at a lower
temperature as specified in the Purchase Order. The required minimum all heat average full
size absorbed energy value (based on a set of three specimens) for transverse body specimen
shall be the greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In case longitudinal
specimen is applicable as per Table 14 of API Spec. SL, the minimum average absorbed
energy value shall be 1.5 times that applicable for transverse specimen. The required
minimum average full size absorbed energy value for weld and HAZ specimen shall also be the
greater of SR 19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual
absorbed energy value of the three specimens shall not be less than 80% of the value
specified.

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

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APPENDIX-I
MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)
1.1 General
1.1.1 Marking shall also include API monogram, Purchase Order number, item number, pipe
number, wall thickness (mm), heat number and weight.
1.2 Location of Markings
Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis.
Stencil marking shall be placed on the inside surface length except that on pipe size
smaller than 16, marking may either be placed on inside or outside.
Paint used for stencil marking shall withstand a temperature up to 250°C 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)
MANUFACTURING PROCEDURE SPECIFICATION

A Manufacturing Procedure Specification (MPS) outlining the successive steps and associated
inspection procedures from steel making to finished line pipe shall be prepared and submitted
to Purchaser for approval prior to start of production. Manufacture of pipes shall start only
after the approval of Manufacturing Procedure. The approved Manufacturing Procedure shall
be strictly followed in all phases of the production of pipes.
The manufacturing procedure shall as a minimum include the following information.
- Steel/Plate/skelp maker and plant at which steel is produced.
- Steel making process with details of secondary refining process and continuous casting
process, nominal weight of each heat.
- Target chemistry, range of intentionally added elements, limits on heat and product analysis
to be
placed on steel maker.
- Plate/skelp rolling procedure indicating number of passes, their temperature and thickness
reduction
in each pass required by Controlled Rolling Procedure and the finishing temperature.
- Heat treatment procedure document established as per para 5.4.
- Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment including
details of
equipment, techniques, scanning pattern, probe frequency, scanning sensitivity, reference
standard for
calibration, dynamic calibration procedure, method of marking defects and indicating loss of
coupling,
inspection and recording.
- Pipe making procedure including plate edge preparation, forming and any other special
process
proposed.
- Welding procedure specification including the details of welding process, brand name,
classification, size and grade of filler metal and flux, speed of welding, number of electrodes
and polarity of each electrode, welding current and voltage for each wire, edge preparation,
tack welding method and spacing of tack weld, details of seam tracking system for both inside
and outside welding, method of
checking the setup of the system, limits of internal and external weld reinforcement etc.

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In addition to the WPS carried out at mill WPS & PQR shall be carried out at the pipe mill by
approved
welders of the EPC Contractor to establish the weldability of pipe.
EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the pipe
mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his responsibility
of carrying out WPS / PWR at site.
- Method of weld defect removal.
- Detailed methodology of cold expansion.
- Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment including
details of equipment, scanning pattern, probe frequency, scanning sensitivity, calibration
pipe, extent of weld length at pipe ends not covered by all probes, method of marking defect
and indicating loss of coupling,
inspection and records.
- Full details of radiographic testing equipment including radiographic film.
- Dimensional tolerances, frequency of checking, measurement and record in a tabular form
including
details of instruments and equipments proposed.
- Detail of techniques proposed for measurement of end square ness and peaking at the
welds.
- Hydrostatic testing including details of testing equipment, procedure and the relevant test
pressure
calculations.
- Marking details.
- Handling, storage and shipment procedure.
- Production Report Formats.
- Complete details of computerized pipe tracking system.
Note: In the event of small quantities of pipe ordered against this specification, the
requirements of submission of manufacturing procedure details can be moderated subject to
agreement between Purchaser and Manufacturer.

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ANNEXURK -II(NEW)
FIRST DAY PRODUCTION TESTS
Two lengths each of completely finished pipes of first day's production from two different
heats (i.e. a total of four pipe lengths) shall be selected at random for testing to verify that the
manufacturing procedure results in the quality of pipes which are in complete compliance with
this specification. The pipes thus tested shall be considered to be the test pipes required per
heat or per lot as per relevant clauses of this specification.
These first day's production tests shall be repeated upon any change in the manufacturing
procedure as deemed necessary by Purchaser Representative. The first day production tests
shall be carried out on pipes for each wall thickness, each diameter and each grade of steel. In
addition ,change of width of coil shall also call for first day production tests.
The Manufacturer shall submit to Purchaser a report giving the results of all tests mentioned
below. The report shall be agreed and signed by Purchaser Representative, prior to start of
regular production.
Note: In the event of small quantities of pipes ordered against this specification, like those for
bends and other similar applications, as specifically called out in the Purchase Order, the first
day production test shall not be carried out. Pipes in such case shall be accepted based on
regular production tests.
The various tests to be conducted on each pipe shall be as follows. The test method and
acceptance values shall be as per this specification unless specified differently in this
Annexure.
a. Visual Examination
All pipes shall be examined visually for dimensional tolerances and apparent surface defects.
b. Ultrasonic Examination
The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic equipment.
All ultrasonic indications suggesting imperfections in the weld shall be carefully investigated
against the corresponding points on the radiographs. If the ultrasonic indication cannot be
fully explained from the radiograph, a cross section of the weld, at the location of the above-
mentioned 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, +20°C for shear area to produce full transition curve. The value at the test
temperature specified in SR 6 of API Spec 5L duly modified in this specification shall be
complied with. For other temperatures, the value shall be for information only.
(Note: This test is to be carried out only when required as per para 6.2.5.3 of this
specification)
vi. Hardness test shall be conducted on selected pipes as per requirement of para 6.2.6 of this
specification.
e. In addition, all the tests and inspections require to be conducted as per this
specification shall be conducted on all the pipes selected for testing during first day production
test.
f. In case of any test failure, no re-testing shall be applied and the entire first day
production shall be rejected.

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ANNEXURE III (NEW)
INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING

The following information as applicable shall be furnished at Bid stage with respect to line pipe
to be
supplied.
- Name(s) of proposed Manufacturer(s)
- Authorization letter(s) from Manufacturer(s) where applicable.
- Authorization letter(s) from Manufacturer(s) of steel plates, in case plate manufacturing
facility is not
an integral part of the Supplier’s 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

METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

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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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Abbreviations:

ASTM American Society for Testing and Materials

API American Petroleum Institute

ID Inside Diameter

HSAW Helical 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

2 REFERENCES

5 PROCESS OF MANUFACTURE AND MATERIAL

6 MATERIAL REQUIREMENTS

7 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES

9 INSPECTION AND TESTING

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 PROCEDUR (NORMATIVE)

APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR 5 FRACTURE TOUGHNESS TESTING (CHARPY V-NOTCH) FOR


PIPES OF SIZE 4½ OR LARGER

SR 6 DROP WEIGHT TEAR TESTING ON WELDED PIPE OF SIZE


20 OR LARGER, GRADE X52 OR HIGHER.

SR 7 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)
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ANNEXURE-I MANUFACTURING PROCEDURE SPECIFICATION

ANNEXURE-II FIRST DAY PRODUCTION TESTS (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. SCOPE

1.1 PURPOSE AND COVERAGE

This specification establishes the minimum requirements for the manufacture of helical
(spiral) seam submerged arc welded steel line pipe in accordance with the requirements
of API (American Petroleum Institute) Specification 5L, Forty-Third Edition, 2004 and
makes restrictive amendments to API Spec. 5L. Unless modified and or deleted by this
specification, the requirements of API Spec. 5L shall remain applicable.

The sections, paragraphs and appendices contained herein have the same numbering
that of API Spec 5L in order to facilitate reference. Additional requirements, which are
not specified in API Spec 5L, have also been numbered and marked as "(New)".

The coverage by this specification is limited to line pipe to be used in onshore pipelines
transporting non-sour hydrocarbons in liquid or gaseous phase.

The Manufacturer shall have a valid license to use API Monogram in accordance with
the requirements of API Spec. 5L, Forty-Third Edition, 2004 on line pipe as Product
Specification Level PSL 2.

1.2 PRODUCT SPECIFICATION LEVEL (PSL)

Line pipe supplied to this specification shall conform to Product Specification Level PSL
2.

1.3 GRADE

This specification is applicable to PSL 2 line pipes of grade B through X70.

1.4 DIMENSIONS

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

2.0 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 for the Acceptance Level for Internal


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Imperfection in Steel Plate, Strip and Wide Flats, based on
Ultrasonic Testing.
ASME IX : Boiler & Pressure Vessel code: Welding & brazing
quality.

ASME B31.8 : Gas Transmission & Distribution piping system.

OISD – 141 : Oil Industries safety distribution piping system

API RP 5 L1 : Recommended practice for railroad transmission of


line pip

5 Process of Manufacture and Material

Following paragraphs of API Spec 5L shall be applicable to the line pipe manufactured
as per this specification:

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

5.4 HEAT TREATMENT

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

5.5 SKELP END WELDS IN HELICAL SEAM PIPE

Junctions of skelp end weld and helical seam welds in finished pipe are not permitted.

6 Material Requirements

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)

C 0.16 max

Mn 1.50 max. (For Grade B to X52)

1.60 max (For Grade X56 to X70)

Si 0.15 min

0.45 max

S 0.015 max

P 0.02 max

Al 0.07 max
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Nb 0.05 max.

V 0.08 max.

Ti 0.04 max. (For Grade B to X60)

0.06 max. (For Grade X65 to X70)

Cr 0.20 max.

Mo 0.10 max.

Cu 0.35 max

Ni 0.20 max

N 0.012 max

B 0.0005 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)

If alloying elements other than those specified in Table 2B above are added to the
steel, the limits of the additional components shall be agreed with the Purchaser.

Note: i (New)

Minimum for Si is not applicable for Al killed steel.

6.1.2 Elements Analysed

For heat analysis and product analysis, all the elements listed in Table 2B of this
specification shall be analyzed and reported, even if those are not purposely added but
are present as residuals only.

6.1.3 Carbon Equivalent (PSL 2 Only)


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6.1.3.1 Calculation of Carbon Equivalent

Boron content shall be considered in CE (PCM) formula even if it is less than 0.0005%.

6.1.3.2 Maximum Carbon Equivalent

For pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the
following limits:

CE (Pcm) ≤ 0.20

CE (IIW) ≤ 0.40

6.2 MECHANICAL PROPERTIES

6.2.1 Tensile Properties

The finished pipe shall conform to the requirements of Table 3B of API Spec 5L and as
modified herein.

The actual yield strength shall be as close as possible to the specified minimum yield
strength (SMYS) but in no case it shall exceed the limits specified here under:

API Spec 5 L Grade Permissible in excess of SMYS. psi (MPa)

Up to and including X46 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 pipe shall not exceed
0.90, when tested using cylindrical all weld specimen.

The ultimate tensile strength of the weld shall be equal to or better than the specified
minimum ultimate tensile strength of the base metal.

The minimum elongation of base metal shall be determined in accordance with the
formula given in foot note (a) of Table-3B and shall comply with the minimum values of
API Spec 5L Appendix D. However elongation in no case shall be less than 20%. API
Spec 5L Appendix D stands modified accordingly.

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6.2.5 Fracture Toughness Tests

6.2.5.2 Charpy Impact Tests for PSL 2

f. (New)

For all pipe sizes and specified wall thickness, additional fracture toughness
requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L
and as modified in this specification shall be applicable for body, weld and heat affected
zone.

6.2.5.3 Supplementary Fracture Toughness Tests

For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test for
determination of Shear Area, in accordance with Supplementary Requirement SR 5A of
API' Spec 5L and as modified in this specification shall be performed. In addition,
whenever line pipes are specified for hydrocarbon service in gaseous phase and
Liquefied Petroleum Gas (LPG) service in Purchase Order, Drop Weight Tear Test in
accordance with Supplementary Requirements SR 6 of API Spec 5L and as modified in
this specification shall be also performed for all pipe size, grade and wall thickness.

6.2.6 Metallographic Examination

6.2.6.1(New)

A test specimen for metallographic & hardness examination shall be taken transverse
to the helical weld, from one finished pipe from each lot of 50 pipes per heat or at least
once per operating shift (12 hrs maximum) whichever is occurring more frequently and
whenever changes of grade, diameter or wall thickness are made and whenever
significant excursions from operating heat treatment conditions are encountered. The
specimen extraction shall be as per Fig. 6.2.6.1 of this specification. The specimen shall
be suitably ground, polished and etched to reveal the macro-structure. The specimen
shall be visually examined using a minimum 10X magnification to provide evidence that
proper fusion has been obtained for the full thickness, and there is proper interpretation
of passes, their alignment and texture of weld zone. In case imperfections or defects
are observed, it will become a cause for re-evaluation of welding parameters and heat
treatment as deemed necessary by Purchaser's Representative.

6.2.6.2(New)

Vickers hardness tests shall be carried out on each specimen taken for metallographic
examination in accordance with ASTM E-92, at locations indicated in Fig. 6.2.6.2 of this
specification i.e. at weld, heat affected zone and body. Indentation in the Heat Affected
Zone shall start as close to the fusion line as possible. The resulting Vickers hardness

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value at any point shall not exceed 248 HV10. Modalities of retest shall be in accordance
with para 9.12.2 of API Spec. 5L.

6.2.7 Residual Stress Test (New)

Helical pipes shall meet the testing and minimum acceptance criteria set forth in this
paragraph. The residual stress test shall be carried out on the pipe after hydrostatic
test.

6.2.7.1 Testing Frequency (New)

One test shall be carried out at the beginning of each shift. Minimum of one test shall
be carried out for pipes of each grade, size and specified wall thickness. In addition,
whenever the production line settings are changed, the first produced pipe shall be
tested for residual stress.

6.2.7.2 Test Specimen (New)

The teat specimen shall be 150mm wide ring cut from one end of the pipe. The
specimen shall either be cut using flame cutting torch or by sawing from the parent
pipe.

6.2.7.3 Testing (New)

The specimen ring shall be severed by flame cutting or sawing parallel to the
longitudinal axis of the pipe. The cut shall be 180 degree from the spiral weld.
(Specimen ring shall be allowed to cool down to ambient temperature prior to cutting)

6.2.7.4 Computation of Residual Stress (New)

The increase in circumference, if any, after severing shall be measured using fiducial
marks of known separation on the specimen prior to severing. The residual stress then
shall be calculated using following formula.

S = {(E*t*C)/(12.556 *R2)}-{(F*R2)/t}

Where:

S - Residual Stress, kPa (psi)

C - Increase in circumference, mm (in)

t - Specified wall thickness, mm (in)

E - Young's Modulus of Elasticity, 2 x 108kPa, (29 x 106psi)


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R - Pipe Radius, mm (0.5 * Specified outside diameter), mm (in)

F - 0.1154 in SI units, (0.425 in conventional units)

6.2.7.5 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 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 Spec 5L, Table 7 stands modified accordingly.

Size Tolerance

18 ± 3mm

> 20 and <36 + 3 mm, - 0.25% of specified OD

>36 ± 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
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
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length between 10.0mand 11.5 m can also be accepted for a max. of 5% of the
ordered quantity. The minimum average length of the entire ordered quantity in any
case shall be 12.0 m. API Spec 5L Table 11 shall not be applicable. Overall length
tolerance shall be (-) Zero and (+) One pipe length to complete the ordered quantity.

Each pipe shall be measured for conformance to above requirements and all
measurements shall be recorded.

7.6 STRAIGHTNESS

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

7.7 JOINTERS

Jointers on pipes are not permitted.

7.8 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

Forming and welding operations shall be conducted to minimize coil edge offset and
distortion and peaking at the helical or spiral seams. The manufacturer shall provide the
appropriate tooling with 'Vee’ blocks and calibrated dial indicators needed to measure
the distortion and misalignment at the seam. All pipes shall be checked for offset of
skelp edges. Offset shall be measured and recorded at least 3 times per operating shift
(12 hours maximum). Measurements shall be taken at two locations (at a distance of
one to two diameters from each end) on each pipe joint. In case of unacceptable
offsets, the manufacturer shall adjust the forming and welding equipment.

7.8.3 Out-of-Line Weld Bead for Pipe with Filler Metal Welds

A misalignment of weld seam exceeding 3.5 mm shall be rejected. The misalignment


shall be measured on radiographic film and calculated using the formula (a+b)/2 where
‘a’ and ‘b' are the relative offsets of the outside edges of the seam (refer Figure 7.8.3 of
this specification). All pipes shall be checked for out-of-line weld bead and shall be

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measured and recorded at least 3 times per operating shift (12 hours maximum).

Checking of the weld seam misalignment shall also be carried out on metallographic
examination specimen as stated at para 6.2.6.

7.8.4 Height of Outside and Inside Weld Beads - Submerged Arc Welds

The maximum height of outside and inside weld bead shall not be more than 3.2 mm
(1/8 in.) for all specified wall thickness. All pipes shall be checked for weld bead height
using a template having a cut out for weld bead and shall be measured and recorded at
least 3 times per operating shift (12 hours maximum).

7.8.8 Hard Spots

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

7.8.9 Cracks, Sweats and Leaks :

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

7.8.10 Laminations

Any lamination or inclusion either extending into the face or bevel of the pipe or present
within 25mm from pipe ends is considered defect and pipe containing such defects shall
be cut back until such defects are eliminated.

The acceptance limit and disposition of lamination and other type of defects on the
skelp shall be as per para 9.8.5.4 of this specification.

7.8.12 Undercuts

Undercutting not classified as minor shall be considered a defect. Disposition


shall be as follows:

1. Undercut defects not exceeding 1/32 in. (0.8 mm) in depth and not exceeding
12½% 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 12½% 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

Pipes shall be furnished with plain ends.

7.9.3 Plain Ends

Unless specified otherwise, the pipe ends shall be bevelled as per API Spec. 5L.

In removing the inside burrs at the pipe ends, care shall be taken not to remove excess
metal and not to form an inside cavity or bevel. Removal of excess metal beyond the
minimum wall thickness as indicated in para 7.3 of this specification, shall be a cause
for rebevelling. In case root face of bevel is less than that specified, the pipe ends shall
be rebevelled and rectification by filing or grinding shall not be done.

7.9.6 Bevel Protectors (New)

Both pipe ends of each pipe shall be provided with metallic or high impact plastic
bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a design
such that they can be re-used by coating applicator for providing on externally anti-
corrosion coated pipes subsequent to coating of line pipe.

9 Inspections 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


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9.2.2.1 Sampling Frequency

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

9.2.2.2 Sampling Method

9.2.2.2 2 Welded Pipe

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

9.3 TESTING OF MECHANICAL PROPERTIES

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 >12¾”, Weld Tensile Tests (Column 3 of API Spec 5L) Note "a" of Table 13
shall also be applicable.

9.3.1.4 Transverse Tensile Tests

The transverse tensile tests shall be carried out on flattened rectangular specimen.

9.3.1.5 Weld Tensile Tests

Inside and outside weld reinforcement in excess of pipe wall thickness shall be removed
from the specimen either by grinding or machining. Specimen shall be tested for
ultimate tensile strength only.

A cylindrical all weld tensile test shall be carried out at the time of first day production
test as specified in Annexure-II of this specification to determine the yield strength,
ultimate tensile strength and elongation.

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The cylindrical all weld specimen shall have gauge length, L = 5d, where;

L = gauge length (mm)

D = 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 Fracture Toughness Tests

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 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 Hydrostatic Test Requirements

Test pressure shall be held for a minimum period of 15 seconds for each pipe of all
sizes and grades.

9.4.2 Verification of Hydrostatic Test

The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5
times and maximum range of 4 times the test pressure. The pressure gauge shall be
calibrated by means of a "Dead Weight" tester only and records shall be maintained.

9.4.3 Test Pressure

The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre
stress) generated is at least 95% of SMYS, computed based on the formula mentioned
in API Spec 5L para 9.4.3 (Note 2).
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9.4.5 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 /
OWNER’S
representative during manufacturing.
Minimum Burst Test pressure shall not be less than the actual tensile stress factor
computed pressure.

9.5 DIMENSIONAL TESTING

The measuring equipment requiring calibration or verification under the provisions of


API Spec 5L shall be calibrated with manual instruments at least once per operating
shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's
Representative on request.

9.7 VISUAL INSPECTION

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

9.8 NON DESTRUCTIVE INSPECTION

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

9.8.1 Qualification of Personnel

All personnel performing NDT activities shall be qualified in the technique applied, in
accordance with latest edition of ISO 9712 or ASNT No. ASNT-TCMA or equivalent.

All NDT shall be performed in accordance with written procedures. These procedures
shall have prior approval of the Purchaser.
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Inspector Qualification

Acceptable qualification for NDT inspectors shall be as specified below:

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

Skelp Inspection

The longitudinal edges of the skelp shall be 100% ultrasonically inspected over width of
at least 25 mm from the trimmed skelp edge. Remaining skelp shall be ultrasonically
tested for laminations using an oscillating or straight running pattern of probes, so as to
provide inspection coverage of at least 20% of the skelp surface uniformly spread over
the area.

Alternatively, skelp UT inspection can be performed after pipe forming provided all
applicable requirements as specified above are complied with.

Locations showing indications above the acceptance limits may be re-examined by


manual ultrasonic method. If no defects are located during re-examination the original
findings may be ignored. Additional scanning may be requested by Purchaser's
Representative to check questionable areas.

Ends Inspection

The full circumference of both ends of each pipe after bevelling shall be 100%
ultrasonically tested for laminations from inside over a circumferential band of at least
25 mm width. In addition, full circumference of both ends of each pipe shall be 100 %
ultrasonically tested over a circumferential width of at least 50 mm with angular probes
to detect cracks, in case of non-availability of angular probes at the mill, the full
circumference of both ends of each pipe shall be inspected with magnetic particle
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technique over a circumferential width of at least 50 mm to detect surface cracks.

Bevel Inspection

Bevel face of all pipes shall be inspected by magnetic particle method to detect defects.

Weld Inspection

Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table-24) using


automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5 and as
modified in this specification. Pipe end welds shall be inspected in accordance with Para
9.8.3.1.

Locations showing indications above the allowable limits during ultrasonic inspection
shall be re-examined by radiography, if during production, repeated ultrasonic
indications occur requiring re-inspection by radiography and it appears from
radiographs that the nature of defects causing the ultrasonic indications cannot be
definitely established, the Manufacturer shall prove by other inspection methods (e.g.
by making some cross-sections in accordance with para 6.2.6 of this specification at
locations where such indications occur near the end of the pipe) to the satisfaction of
Purchaser that these are not injurious defects as stipulated in this specification.

9.8.3.1 Pipe End Weld Inspection

Pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual
ultrasonic equipment with same sensitivity and capability as automatic equipment.

Submerged-arc weld seam shall be radio graphically examined for a minimum distance
of 8 in. (200 mm) from each pipe end. The results of radiographic inspection shall be
recorded.

9.8.4 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

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

9.8.5.2 Ultrasonic and Electromagnetic Inspection Reference Standards

The reference standard (calibration pipe) shall have the same specified diameter and
wall thickness as specified for the production pipe being inspected and shall be of
sufficient length to permit calibration of ultrasonic inspection equipment at the speed to
be used in normal production. The reference standard (calibration pipe) shall also be of
the same material, type and have the same surface finish and heat treatment as the
pipe being inspected.

The reference standard for weld UT shall contain machined notches/holes as per as per
Figure 9.8.5.2 of this specification and as given below;

- Two longitudinal inside notches of type N 5 at both edges of weld seam.


- Two longitudinal outside notches of type N5 at both edges of weld seam.
- Two longitudinal notches of type N5 at the centre of the weld seam, one outside and
one inside.
- Two transverse notches of type N5 across the weld seam, one outside and one inside.
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- A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm.

The reference standard for skelp UT shall contain continuous machined notch of 8 mm
width x ½ t depth, where “t”is the specified wall thickness.

The reference standard for skelp edge UT and pipe ends shall have ¼” inch dia FBH x
½ t depth, where “t” is the specified wall thickness.

The calibration shall be performed at following intervals:

a. At the beginning of each operating shift (12 hours maximum).


b. At least once during each operating shift (12 hours maximum).
c. Every time the running of the system gives rise to doubts on its efficiency.

If during the above calibration verification, it is found that the equipment has not
functioned satisfactorily in the opinion of the Purchaser's Representative, all the pipes
or skelp already inspected after the previous verification shall be inspected again at
Manufacturer's cost.

9.8.5.4 Acceptance limits

9.8.5.4.1 Skelp Edges (New)

Acceptance limit for material edge examination shall be as per criteria laid down for
Acceptance Level E2 of BS 5996:1993, which is reproduced hereunder for ready
reference.

1. No individual imperfection of length less than 20 mm shall be considered for


population density assessment.
2. Maximum length of imperfection in any direction shall not exceed 30 mm.
3. Maximum area of individual imperfection shall not exceed 500 mm2.
4. Maximum population density (number of imperfections smaller than the maximum
permissible imperfection size and longer than 20 mm per 1m length) shall not
exceed 4.

Disposition of any defect shall be as per API Spec L, para 9.9 (c) or (d).

9.8.5.4.2 Remaining Skelp (New)

Acceptance limit for material body examination shall be as per criteria laid down for
Acceptance level B4 of BS 5996: 1993 which is reproduced hereunder for ready
reference:

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1. No individual imperfection that does not exceed all of the following dimensions shall
be considered for population density assessment: Area: 300 mm2, Length: 35 mm,
Width : 8 mm. (The length is the dimension at right angles to the scan track and the
width is the dimension parallel to the scan track)
2. Maximum area of any individual discontinuity shall not exceed 1000 mm2.
3. Maximum population density of imperfections smaller than the maximum permissible
imperfection size and larger than the minimum imperfection size per 1 m x 1 m
square shall not exceed 10.
4. Any imperfection exceeding 100 mm in length shall not be acceptable and any
planar imperfection not parallel to the skelp surface is not acceptable.

Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d).

9.8.7 Residual Magnetism Measurement Requirements

The average of the four readings shall not exceed 20 gauss and no one reading shall
exceed 25 gauss when measured with Hall-effect gauss meter. All residual magnetism
measurements shall be recorded.

9.9 DISPOSITION OF PIPE CONTAINING DEFECTS

a. Suitable tools to eliminate defects by grinding shall be used. The repaired area shall
be 100% rechecked by magnetic particle or ultrasonic inspection to ensure complete
removal of defects. However for repair of cosmetic type of defects, MPI may not be
conducted if so directed by Purchaser's Representative on case to case basis. The
pipes having a thickness less than the minimum allowed in accordance with this
specification, after repair by grinding shall be treated for disposition in accordance
with API Spec 5L para 9.9 (c) or (d).
b. Repair welding on parent metal is not permitted.
c. In addition to NTD requirement random radiography of 0.1% of the total length
shall be done. The areas to be radiographed shall be at the sole discretion of Third
Party Inspection Agency.

9.10 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

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/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

REPAIR OF DEFECTS BY WELDING (NORMATIVE)

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 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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APPENDIX-C

REPAIR WELDING PROCEDURE (NORMATIVE)

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

SUPPLEMENTARY REQUIREMENTS (NORMATIVE)

SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4 1/2 or
Larger

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 Flattened specimen shall not be used.

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
+32°F (0°C), 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 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 +32°F (0°C).

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 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 as modified in this specification, with a test temperature of 32°F (0°C)
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

PURCHASER INSPECTION (NORMATIVE)

H.4 Rejection

If Purchaser Representative rejects pipes repeatedly for any recurring cause, this
shall be adequate reason to refuse final inspection of subsequent pipes until the
cause has been investigated and corrective action taken by the Manufacturer.

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APPENDIX-I

MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)

1.0 General

1.1 Marking shall also include Purchase Order number/item number, pipe number, heat
number and weight.

1.2 Location of Markings

Paint used for stencil marking shall withstand a temperature up to 250°C 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 ISO mm from the pipe ends.

1.5 Length

Actual length shall be marked in metres.

1.7 Die Stamping

Additionally, the pipe number shall be placed by cold rolling or low stress dot
marking on the outside surface of the pipe at an approximate distance of 50 mm
from both ends. In case of non-availability of either cold rolling or low stress dot
marking facility in pipe mill, an alternative marking scheme of a permanent nature
may be proposed by the Manufacturer.

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ANNEXURE I (NEW)
MANUFACTURING PROCEDURE SPECIFICATION

A Manufacturing Procedure Specification (MPS) outlining the successive steps and


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

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ANNEXURE -II (NEW)

FIRST DAY PRODUCTION TESTS

Two lengths each of completely finished pipes of first day's production from two
different heats (i.e. a total of four pipe lengths) shall be selected at random for
testing to verify that the manufacturing procedure results in the quality of pipes
which are in complete compliance with this specification. The pipes thus tested shall
be considered to be the test pipes required per heat or per lot as per relevant
clauses of this specification.

These first 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 test.

The Manufacturer shall submit to Purchaser a report giving the results of all tests
mentioned below. The report shall be agreed and signed by Purchaser
Representative, prior to start of regular production.

Note: In the event of small quantities of pipes ordered against this specification, like
those for bends and other similar applications, as specifically called out in the
Purchase Order, the first day production test shall not be carried out. Pipes- in such
case shall be accepted based on regular production tests.

The various tests to be conducted on each pipe shall be as follows. The test method
and acceptance values shall be as per this specification unless specified differently in
this Annexure.

a. Visual Examination

All pipes shall be examined visually for dimensional tolerances and apparent
surface defects.

b. Ultrasonic Examination

The weld seam of all pipes shall be examined ultrasonically by automatic ultrasonic
equipment. All ultrasonic indications suggesting imperfections in the weld shall be
carefully investigated against the corresponding points on the radiographs. If the
ultrasonic indication cannot be fully explained from the radiograph, a cross section
of the weld, at the location of the above-mentioned ultrasonic indication shall be
made in such a way that the nature of the imperfection can definitely be
established.
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c. Radiographic Examination

The weld seam of all pipes shall be examined radio graphically for the entire
length.

d. Mechanical Properties

The mechanical properties of all pipes shall be tested and shall meet the
requirements of this specification. Purchaser Representative will select the places in
pipe from where the test specimen shall be removed.

The following tests shall be conducted:

i.Four (4) weld guided bend test specimen transverse to the helical weld shall be
removed. Of the four specimen, two specimen shall be used for the tact- bend test
and two for the root bend test.
ii.Tensile tests shall be conducted on:

- Two (2) transverse base material specimen.


- Two (2) transverse weld material specimen of the helical weld.
- Two (2) cylindrical all-weld specimen of the helical weld.

iii.Six (6) weld cross-section specimen, three (3) from each end of pipe joint shall be
taken for metallographic examination. Two of these shall be tested for hardness at
room temperature after etching.
iv.Fracture toughness testing specimen shall be extracted as follows:

- Four sets of three transverse specimen each from base metal


- One set of 3 transverse specimen with weld in middle
- One set of 3 transverse specimen with HAZ in middle

The base metal specimen shall be tested at - 40, -10, 0, + 20° C for shear area and
absorbed energy to produce full transition curve. The value at the test temperature
specified in SR 5A and SR 19 of API Spec. 5L and duly modified in this specification
for shear area and absorbed energy respectively shall be complied with. For other
temperatures, the value shall be for information only. The sets of weld and HAZ
specimen shall be tested for absorbed energy only at the same test temperature
applicable as per SR 19 of API Spec. 5L.

v.At points selected by Purchaser, twelve (12) DWTT specimens shall be removed
from base metal in a transverse direction. The sets of 3 base metal specimen shall
be tested at -40, -10, 0, +20°C 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)

INFORMATION TO BE FURNISHED AT THE TIME OF BIDDING

The following information as applicable shall be furnished at Bid stage with respect to line
pipe to be supplied.
- Name(s) of proposed Manufacturer(s)
- Authorisation letter(s) from Manufacturer(s) where applicable.
- Authorisation letter(s) from Manufacturer(s) of skelp, in case skelp manufacturing
facility is not
an integral part of the Supplier’s 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

METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

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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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CONTENTS

S.No. Description Page No.

1 INTENT OF SPECIFICATION 2

2 SCOPE OF WORK 2

3 COVERAGE 2

4 REFERENCES 2

5 MANUFACTURING PROCESS 2

6 INSPECTION & TESTING 3

7 MARKING & DESPATCH 3

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1.0 INTENT OF SPECIFICATION

1.1 This specification establishes the minimum requirements for the manufacture of
Seamless Pipes in accordance with the requirements of API (American Petroleum
Institute) Specification 5L- 2000 (Forty Second Edition).

1.2 Unless modified and referred by this specification the requirements of API Spec. 5L-
2000 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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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 INSPECTION & TESTING

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

GROUP 1 (SEAMLESS,ERW & SPIRAL WELDED)

A
CARBON STEEL
S No. : TEST PRESSURE
MATERIAL STD
(i) ASTM A106 GR.B : ASTM A 530
(ii) API 5L GR.B,SEAMLESS : API 5L
(iii) API 5L,E.R.W : API 5L
(iv) API 5L,SPIRAL : API 5L
(v) ASTM A333 GR.3 & 6,SEAMLESS : ASTM A530

(vi) ASTM A333 GR.3 & 6,E.R.W : ASTM A530

B
SEAMLESS ALLOY STEEL
S No. : TEST PRESSURE
MATERIAL STD
(i) ASTM A335 : ASTM A530
GR.P1,P12,P11,P22,P5,Pg
(ii) ASTM A268 TP 405,TP410 : ASTM A530

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C
SEAMLESS STAINLESS STEEL
S No. : TEST PRESSURE
MATERIAL STD
(i) ASTM A312 GR. TP304 ,304L : ASTM A530
,304H, 316, 316L, 316H, 321, 347

D SEAMLESS NICKEL ALLOY


S No. : TEST PRESSURE
MATERIAL STD
(i) ASTM B161 UNS NO2200 : ASTM B161
(ii) ASTM B165 UNS NO4400 : ASTM B165
(iii) ASTM A167 UNS NO6600 : ASTM B167
(iv) ASTM A407 UNS NO8800 : 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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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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CONTENTS
1 SCOPE
2 REFERENCES
5 PROCESS OF MANUFACTURE AND MATERIAL
6 MATERIAL REQUIREMENTS
7 DIMENSIONS, WEIGHTS, LENGTHS, DEFECTS, AND END FINISHES
9 INSPECTION AND TESTING
10 MARKING
11 COATING AND PROTECTION
12 DOCUMENTS
14 (New) INSPECTIONS OF FIELD TESTS & WARRANTY

APPENDIX-F SUPPLEMENTARY REQUIREMENTS (NORMATIVE)


SR 5 FRACTURE TOUCHNESS TESTING (CHARPY V-NOTCH) FOR PIPES
OF SIZE 4½ 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 ADDITIONAL FRACTURE TOUGHNESS
REQUIREMENTS (TRANSVERSE CHARPY V-NOTCH)
FOR PSL 2 PIPE
APPENDIX-H PURCHASER INSPECTION (NORMATIVE)
APPENDIX-I MARKING INSTRUCTIONS FOR API LICENSEE (NORMATIVE)
ANNEXURE-I MANUFACTURING PROCIDURE
(New)
ANNEXURE-II FIRST DAY PRODUCTION TESTS
(New)
FIGURE 6.2.6.2 LOCATIONS FOR HARDNESS MEASUREMENT
FIGURE 6.2.7 REVERSE BEND TEST
FIGURE 9.8.5.2 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM

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Abbreviations:

ASTM American Society for Testing and Materials


API American Petroleum Institute
ID Inside Diameter
EW Electric 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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1. Scope
1.1 PURPOSE AND COVERAGE
This specification establishes the minimum requirements for the manufacture of
longitudinal seam electric welded steel tine pipe in accordance with the
requirements of API (American Petroleum Institute) Specification 5L Forty-Third
Edition, 2004 and makes restrictive amendments to API Spec. 5L. Unless modified
and or deleted by this specification, the requirements of API Spec. 5L shall remain
applicable.
The sections, paragraphs and appendices contained herein have the same
numbering as that of API Spec SL in order to facilitate reference. Additional
requirements, which are not specified in API Spec 5L, have also been numbered and
marked as "(New)".
The coverage by this specification is limited to line pipe to be used in onshore
pipelines transporting non-sour hydrocarbons in liquid or gaseous phase.
The Manufacturer shall have a valid license to use API Monogram in accordance with
the requirements of API Spec 5L Forty-Third Edition, 2004 on line pipe as Product
Specification Level PSL 2.

1.2 PRODUCT SPECIFICATION LEVEL (PSL)


Line pipe supplied to this specification shall conform to Product Specification
Level PSL 2.
1.3 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 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 : Specification for the Acceptance Level for Internal
Imperfection in Steel Plate, Strip and Wide Flats, based
on Ultrasonic Testing.

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OISD –141 : Oil industry safety Directorate Standard for Design and
Construction Requirements for Cross country Hydrocarbon Pipeline
ASME IX : Boiler & Pressure Vessel code: Welding & brazing quality.
ASME B31.8 : Gas Transmission & Distribution piping system.
API RP 5 L : Recommended practice for railroad transmission of line pipe

5 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:
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)
Line pipe furnished to this specification shall be made from steel produced in basic
oxygen or electric arc furnace. The steel used for manufacture of pipe shall be fully
killed and fine grained with a grain size of ASTM 7 or finer as per ASTM E 112. Steel
shall be made by continuous casting only.

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5.4 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 Material Requirements
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)
C 0.16 max
Mn 1.50 max (For Grade B to X52)
1.60 max (For Grade X56 to X70)
Si 0.15 min
0.45 max
S 0.01 max
P 0.02 max
Al 0.07 max
Nb 0.05 max
V 0.08 max
Ti 0.04 max (For Grade B to X60)
0.06 max (For Grade X65 to X70)
Cr 0.20 max
Mo 0.10 max
Cu 0.35 max
Ni 0.20 max
N 0.012 max
B 0.0005 max
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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)
If alloying elements other than those specified in Table 2B above are added to the
steel, the limits of the additional components shall be agreed with the Purchaser.
Note: i (New)
Minimum for Si is not applicable for Al killed steel.
6.1.2 Elements Analyzed
For heat analysis and product analysis, all the elements listed in Table 2B of this
specification shall be analyzed and reported, even if those are not purposely added
but are present as residuals only.

6.1.3 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:
CE (Pcm) ≤ 0.20 %
CE (IIW) ≤ 0.40 %
6.2 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 Permissible in excess of SMYS. psi (MPa)
Up to and including X46 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.
The minimum elongation of base metal shall be determined in accordance with the

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formula given in the foot note (a) of Table-3B and shall comply with the minimum
values of API Spec 5L Appendix D. However elongation in no case shall be less than
20%. API Spec 5L Appendix D stands modified accordingly.

6.2.2 Flattening Test Acceptance Criteria


Dye penetrate testing may be used to positively confirm the presence of crack,
break or opening.

6.2.5 Fracture Toughness Tests


6.2.5.2 Charpy Impact Tests for PSL 2

f. (New) For all pipe sizes and specified wall thickness, additional fracture toughness
requirements as per Supplementary Requirements Appendix-F SR 19 of API Spec 5L
and as modified in this specification shall be applicable for body, weld and heat
affected zone.

6.2.5.3 Supplementary Fracture Toughness Tests


For pipe of all grades and specified wall thickness, the Charpy V-notch Impact Test
for determination of Shear Area in accordance with Supplementary Requirement SR
5 A of API Spec 5L and as modified herein shall be performed. In addition,
whenever line pipes are specified for hydrocarbon service in gaseous phase and
Liquefied Petroleum Gas (LPG) service in Purchase Order for pipe size 16” and
larger, Drop Weight Tear Test (DWTT) in accordance with Supplementary
Requirements SR 6 of API Spec 5L and as modified in this specification shall be also
performed for all grades and wall thickness.

6.2.6 Metallographic Examination


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
t - 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 Dimensions, Weights, Lengths, Defects and End Finishes


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 ½) 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 and≤18 ± 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
≤10¾ 2mm
>12¾ 3 mm
Out of roundness tolerance apply to maximum and minimum diameters as measured
with a bar gauge, caliper or device measuring actual maximum and minimum
diameter. Out of roundness tolerance indicated in API 5L Table-8 stands deleted.
Each pipe shall be measured for conformance to above requirements. All dimensions
and tolerances shall be measured and recorded at least 3 times per operating shift
(12 hrs maximum).

7.3 WALL THICKNESS


In addition to API requirements, the wall thickness of each pipe shall be checked
along the circumference at both ends and at the mid location of pipe body at 12
o'clock, 3 o'clock, 6 o'clock and 9 o'clock positions. The wall thickness tolerance shall
comply with the requirements of this specification.
The tolerances on specified wall thickness shall be (+)15% and (-) 0%. API Spec 5L
Table 9 stands cancelled.
Wall thickness shall be measured and recorded at least 3 times per operating shift
(12 hours maximum).

7.5 LENGTH
All pipes shall be supplied with length between 11.5 m and 12.5 m. However pipe
with length between 10.0 m and 11.5 m can also be accepted for a max. of 5% of
the ordered quantity. The minimum average length of the entire ordered quantity in
any case shall be 12.0m. API Spec 5L Table 11 shall not be applicable. Overall
length tolerance shall be (-) Zero and (+) One pipe length to complete the ordered
quantity.
Each pipe shall be measured for conformance to above requirements and all
measurements shall be recorded.

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

7.7 JOINTERS
Jointers on pipes are not permitted.

7.8 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 skelp edges. Offset shall be measured and
recorded at least 3 times per operating shift (12 hours maximum).

7.8.5 Height of Flash of Electric Welded Pipe


Each pipe shall be checked for conformance of height of flash. Height of flash shall
be measured and recorded at least 3 times per operating shift (12 hours maximum).
7.8.7 Trim of Inside Flash of Electric Welded Pipe and Trim of Inside Weld
Reinforcement of Laser Welded Pipe
Each pipe shall be checked for conformance of depth of trim. Depth of trim shall be
measured and recorded at least 3 times per operating shift (12 hours maximum).
7.8.8 Hard Spots
Any hard spot having a minimum dimension greater than 2 in. (50.8 mm) in any
direction and hardness greater than 248 HV10 shall be rejected. The section of pipe
containing the hard spot shall be removed as a cylinder.

7.8.9 Cracks, Sweats and Leaks


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

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Any lamination or inclusion either extending into the face or bevel of the pipe or
present within 25 mm from pipe ends is considered defect and pipe containing such
defects shall be cut back until such defects are eliminated.
The acceptance limit and disposition of lamination and other type of defects on the
skelp/pipe body shall be as per para 9.8.5.4 of this specification.

7.8.11 Arc Burns


Arc burns produced during the manufacturing of pipes are injurious defects and shall
be disposed off in accordance with the requirements of API Spec 5L para 9.9 (c) or
(d). As a reference method for conforming the existence of an arc burn, the area
shall be buffed with wire brush or sanding disc and etched with 5 percent nital
solution. However, arc burns can be considered for acceptance, in case the same is
recrystallized by seam heat treatment. In such case, the Manufacturer shall
demonstrate the recrystallization to Purchaser by taking a sample as per para
6.2.6.1 (New) of this specification.

7.8.14 Other Defects


Any imperfection (measured from the surface) with a depth greater than 5 % of the
specified thickness of the pipe shall be considered a defect and shall be repaired in
accordance with API Spec 5L para 9.9 and as modified in this specification.
7.9 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 and not to form an inside cavity or bevel. Removal of excess metal
beyond the minimum wall thickness as indicated in para 7.3 of this specification,
shall be a cause for re-bevelling. In case root face of bevel is less than that
specified, the pipe ends shall be re-bevelled and rectification by filing or grinding
shall not be done.

7.9.6 Bevel Protectors (New)


Both pipe ends of each pipe shall be provided with metallic or high impact plastic
bevel protectors as per Manufacturer's standard. Bevel protectors shall be of a
design such that they can be re-used by coating applicator for providing on
externally anti-corrosion coated pipes subsequent to coating of line pipe.

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

9.2.2 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
Samples used for product analysis shall be taken from finished pipes. Samples for
product analysis from skelp may be used provided the traceability of samples is
guaranteed.

9.3 TESTING OF MECHANICAL PROPERTIES


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 Transverse Tensile Tests


The transverse tensile tests shall be carried out on flattened rectangular specimen.
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 Fracture Toughness Tests
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. When either full size or sub-size
transverse specimen as per API Spec 5L, Table 14 is not possible to obtain,
transverse specimen of either Size 1/3 or 1/4 Size, whichever is maximum possible,
may be obtained.
When such sub-size specimens are used, the acceptance of the individual / average
absorbed energy values shall be established as per API Spec 5L para 9.10.4 and as
modified in this specification.

9.3.5.2 Charpy Testing Frequency


The minimum test frequency shall be one test (a set of three specimen each for
body, weld and HAZ) per heat per lot of 100 pipes per combination of pipe size and
specified wall thickness.

9.4 HYDROSTATIC TESTS


9.4.1 Hydrostatic Test Requirements
Test pressure shall be held for a minimum period of 15 seconds for all sizes and
grades of pipes.
9.4.2 Verification of Hydrostatic Test
The pressure gauge used for hydrostatic testing shall have a minimum range of 1.5
times and maximum range of 4 times the test pressure. The pressure gauge shall be
calibrated by means of a "Dead Weight" tester only and record shall be maintained.
9.4.3 Test Pressure
The test pressure for all sizes and grades of pipe shall be such that hoop stress
(fibre stress) generated is at least 95% of SMYS, computed based on the formula
mentioned in API Spec 5 L para 9.4.3 (Note 2).
9.5 DIMENSIONAL TESTING
The measuring equipment requiring calibration or verification under the provisions of
API Spec 5L shall be calibrated with manual instruments at least once per operating
shift (12 hours maximum). Such calibration records shall be furnished to Purchaser's
Representative on request.

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

9.8.1 Qualification of Personnel


All personnel performing NDT activities shall be qualified in the technique applied, in
accordance with latest edition of ISO 9712 or ASNT No. ASNT-TC-1A or equivalent.
All NDT shall be performed in accordance with written procedures. These procedures
shall have prior approval of the Purchaser.
Inspector Qualification
Acceptable qualification for NDT inspectors shall be as specified below:
(i) For UT
For UT, at least one level III qualified inspector shall be available to the mill for
overall supervision. A level II inspector is required for shift supervision, manual weld
inspection and calibration of all systems (both manual and automated).

(i) For all other NDT methods


Evaluation of indications : 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 pipe shall be performed after hydro testing.

Plate/Skelp Inspection
The longitudinal edges of the plate/skelp shall be 100% ultrasonically inspected over
a width of at least 25 mm from the trimmed plate/skelp edge. Remaining plate/skelp

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shall be ultrasonically tested for laminations using an oscillating or straight running
pattern of probes, so as to provide inspection coverage of at least 20% of the
plate/skelp surface uniformly spread over the area.
Locations showing indications above the acceptance limits may be re-examined by
manual ultrasonic method. If no defects are located during re-examination, the
original findings may be ignored. Additional scanning may be requested by
Purchaser's Representative to check questionable areas.

Pipe Ends Inspection


The full circumference of both ends of each pipe after beveling shall be 100%
ultrasonically tested for laminations from inside over a circumferential band of at
least 25 mm width. Alternatively the pipe may be tested from outside prior to
bevelling, in which case a band of at least 50 mm wide shall be tested to include the
eventual bevelled area.
Bevel Inspection
Bevel face of all pipes shall be inspected by magnetic particle method to detect
defects.
Weld Inspection
Electric welds shall be inspected by ultrasonic methods (Refer Table 24) using
automatic ultrasonic equipment in accordance with API Spec 5L para 9.8.5, API Spec
5L SR 17 (Appendix F) and as modified in this specification. Pipe end welds shall be
inspected in accordance with Para 9.8.3.1.
9.8.3.1 Pipe End Weld Inspection
Pipe ends not covered by automatic ultrasonic equipment shall be inspected by
manual ultrasonic equipment with same sensitivity and capability as automatic
equipment.
9.8.5 Ultrasonic and Electromagnetic Inspection
9.8.5.1 Equipment
All automatic ultrasonic equipment shall have an alarm device, which continuously
monitors the effectiveness of the coupling. The equipment for the automatic
inspection shall allow the localization of both longitudinal and transverse defects
corresponding to the signals exceeding the acceptance limits of the reference
standard. The equipment shall be fitted with a paint spray or automatic marking
device and alarm device for areas giving unacceptable ultrasonic indications. All
ultrasonic testing equipment shall be provided with recording device. In addition, an
automatic weld tracking system shall be provided for correct positioning of the
probes with respect to weld centre.
9.8.5.2 Ultrasonic and Electromagnetic Inspection Reference Standards

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The reference standard (calibration pipe) shall have the same specified diameter
and wall thickness as specified for the production pipe being inspected and shall be
of sufficient length to permit calibration of ultrasonic inspection equipment at the
speed to be used in normal production. The reference standard (calibration pipe)
shall also be of the same material, type and have the same surface finish and heat
treatment as the pipe being inspected.
The reference standard for weld UT shall contain machined notches as per as per
Figure 9.8.5.2 of this specification and as given below:

One longitudinal inside notch of type N10 at the weld line


One longitudinal outside notch of type N10 at the weld line
The reference standard for skelp/pipe body UT shall contain continuous machined
notch of 8 mm width x ½ t depth, where‘t’ 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 ½ t depth, where’t’ is the specified wall
thickness.
The calibration shall be performed at following intervals:
a. At the beginning of each operating shift (12 hours maximum).
b. At least once during each operating shift (12 hours maximum).
c. Every time the running of the system gives rise to doubts on its efficiency.
If during the above calibration verification, it is found that the equipment has not
functioned satisfactorily in the opinion of the Purchaser's Representative, all the
pipes or skelp already inspected after the previous verification shall be inspected
again at Manufacturer's cost.

9.8.5.4 Acceptance limits


9.8.5.4.1 Skelp Edges/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.)
2. Maximum area of any individual discontinuity shall not exceed 1000 mm2.
3. Maximum population density of imperfections smaller than the
maximum permissible imperfection size and larger than the minimum
imperfection size per 1 m x 1 m square shall not exceed 10.
4. Any imperfection exceeding 100 mm in length shall not be acceptable and any
planar imperfection not parallel to the plate surface is not acceptable.
Disposition of any defects shall be as per API Spec 5L para 9.9 (c) or (d).

9.8.7 Residual Magnetism Measurement Requirements


e. 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


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

12.3 PRODUCTION REPORT (New)


The Manufacturer shall provide six copies of production report in English language
indicating at least the following for each pipe. International System of units (SI)
shall be adopted.
- Pipe number
- Heat number from which pipe is produced
- Pipe length and weight.
- Pipe grade
The Manufacturer shall provide six copies of acceptance certificates which shall
include the results of all tests required as per this specification and performed on
delivered material giving details of, but not limited to, the following:
- All test certificates as per SR 15.1.
- Certified reports of dimensional, workmanship and defects inspection.
- Data on test failures, rejected heats/lots, etc.
- All other reports and results required as per this specification.
The certificates shall be valid only when signed by the Purchaser's Representative.
Only that pipes, which have been certified by the Purchaser's Representative shall
be dispatched from the pipe mill.
In the event of small quantities of pipes supplied against this specification, like those
for bends and other similar applications, as specifically called out in the Purchase
Order, the production report may consist of only test certificates required as per SR
15 of API Spec 5L and other test reports/results required as per this specification.

12.4 LINE PIPE TRACEABILITY DATA (New)


The manufacturer shall establish and follow procedures for maintaining heat and lot
identity of all pipes as per Supplementary Requirements SR 15.2 of API Spec. 5L.

14 Inspection of Field Tests & Warranty (New)

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Purchaser shall be reimbursed by Manufacturer for any pipe furnished on this order
that fails under field hydrostatic test if such failure is caused by a
material/manufacturing defect in the pipe. The reimbursement cost shall include
pipe, labour and equipment rental for finding, excavating, cutting out and
installation of replaced pipe in position. The field hydrostatic test pressure will not
exceed that value which will cause a calculated hoop stress equivalent to 95 percent
of specified minimum yield strength.
In case Manufacturer so desires, he will be advised at least two weeks in advance so
that his Representative may witness the hydrostatic test in field, however, the
testing and leak (if any) finding and repair operation shall not he postponed because
of absence of the Manufacturer's Representative.

APPENDIX-F
SUPPLEMENTARY REQUIREMENTS (NORMATIVE)
SR5 Fracture Toughness Testing (Charpy V-Notch) for Pipe of Size 4½ 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 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
+32°F (0°C). 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 Drop Weight Tear Testing (DWTT) on Welded Pipe
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 +32°F (0°C).
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 32°F (0°C)
or at a lower temperature as specified in the Purchase Order. The required minimum
all heat average full size absorbed energy value (based on a set of three specimens)
for transverse body specimen shall be the greater of SR 19.1 (a) and SR 19.1 (b) of
API Spec 5L. In case longitudinal specimen is applicable as per Table 14 of API
Spec. 5L, the minimum average absorbed energy value shall be 1.5 times that
applicable for transverse specimen. The required minimum all heat average full size
absorbed energy value for weld and HAZ specimen shall also be the greater of SR
19.1 (a) and SR 19.1 (b) of API Spec 5L. In addition, the lowest individual absorbed
energy value of the three specimens shall not be less than 80% of the value
specified.

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

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APPENDIX-I
MARKING INSTRUCTIONS FOR API LICENSEES (NORMATIVE)
1.1 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 Location of Markings


Marking shall be paint stenciled on length of the pipe at right angles to the pipe axis.
Stencil marking shall be placed on the inside surface length except that on pipe size
smaller than 16, marking may either be placed on inside or outside.
Paint used for stencil marking shall withstand a temperature up to 2505C expected
to be experienced during further external anti-corrosion coating operations of line
pipe by coating applicator.

1.3 Sequence of Marking


1.3.4 SPECIFIED DIMENSIONS
Actual pipe weight in kg shall also be marked.

1.35 GRADE AND CLASS


A colour code band shall be marked on inside surface of finished pipe for
identification of pipes of same diameter but different wall thickness, as indicated in
the Purchase Order. The colour code band shall be 50 mm wide and shall be marked
at a distance of 150 mm from the pipe ends.

1.5 Length
Actual length shall be marked in metres.
1.7 Die Stamping
Additionally, the pipe number shall be placed by cold rolling or low stress dot
marking on the outside surface of the pipe at an approximate distance of 50 mm
from both ends. In case of non-availability of either cold rolling or low stress dot
marking facility in pipe mill, an alternative marking scheme of a permanent nature
may be proposed by the Manufacturer.

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ANNEXURE I (NEW)
MANUFACTURING PROCEDURE SPECIFICATION

A Manufacturing Procedure Specification (MPS) outlining the successive steps and


associated inspection procedures from steel making to finished line pipe shall be
prepared and submitted to Purchaser for approval prior to start of production.
Manufacture of pipes shall start only after the approval of Manufacturing Procedure.
The approved Manufacturing Procedure shall be strictly followed in all phases of the
production of pipes.
The manufacturing procedure shall as a minimum include the following information.
- Steel/Plate/skelp maker and plant at which steel is produced.
- Steel making process with details of secondary refining process and continuous
casting process, nominal weight of each heat.
- Target chemistry, range of intentionally added elements, limits on heat and product
analysis to be placed on steel maker.
Skelp rolling procedure indicating number of passes, their temperature and thickness
reduction in each pass required by Controlled Rolling Procedure and the finishing
temperature.
- Heat treatment procedure document established as per para 5.4.
- Ultrasonic testing of plates/skelp and pipes using automatic and manual equipment
including details of equipment, techniques, scanning pattern, probe frequency, scanning
sensitivity, reference standard for calibration, dynamic calibration procedure, method of
marking defects and indicating loss of coupling, inspection and recording.
- Pipe making procedure including skelp edge preparation, forming and any other
special process proposed.
- Welding procedure specification including the details of welding process, brand name,
classification, size and grade of filler metal and flux, speed of welding, number of
electrodes and polarity of each electrode, welding current and voltage for each wire,
edge preparation, tack welding method and spacing of tack weld, details of seam
tracking system for both inside and outside welding, method of checking the setup of
the system, limits of internal and external weld reinforcement etc.
In addition to be WPS carried out at mill WPS & PQR shall be carried out at the pipe
mill by approved welders of the EPC Contractor to establish the weldability of pipe.
EPC Contractor accordingly arrange for the welders to carry out the WPS / PQR at the
pipe mill. Establishing the WPS of pipe mill doesn’t absolve the EPC contractor of his
responsibility of carrying out WPS / PWR at site.

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- Method of weld defect removal.
- Ultrasonic testing of longitudinal weld seam of pipe using automatic equipment
including details of equipment, scanning pattern, probe frequency, scanning
sensitivity, calibration pipe, extent of weld length at pipe ends not covered by all
probes, method of marking defect and indicating loss of coupling, inspection and
records.
- Full details of radiographic testing equipment including radiographic film.
- Dimensional tolerances, frequency of checking, measurement and record in a tabular
form including details of instruments and equipments proposed.
- Detail of techniques proposed for measurement of end square ness and peaking at the
welds.
- Hydrostatic testing including details of testing equipment, procedure and the relevant
test pressure calculations.
- Marking details.
- Handling, storage and shipment procedure.
- Production Report Formats.
- Complete details of computerized pipe tracking system.
Note: In the event of small quantities of pipe ordered against this specification, the
requirements of submission of manufacturing procedure details can be moderated
subject to agreement between Purchaser and Manufacturer.

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ANNEXURE-lI (NEW)
FIRST DAY PRODUCTION TESTS
Two lengths each of completely finished pipes of first day's production from two
different heats (i.e. a total of four pipe lengths) shall be selected at random for
testing to verify that the manufacturing procedure results in the quality of pipes
which are in complete compliance with this specification. The pipes thus tested shall
be considered to be the test pipes required per heat or per lot as per relevant
clauses of this specification.
The first day's production tests shall be repeated upon any change in the
manufacturing procedure as deemed necessary by Purchaser Representative. The
first day production tests shall be carried out on pipes for each wall thickness, each
diameter and each grade of steel,
The Manufacturer shall submit to Purchaser a report giving the results of all tests
mentioned below. The report shall be agreed and signed by Purchaser
Representative, prior to start of regular production.
Note: In the event of small quantities of pipes ordered against this specification, like
those for bends and other similar applications, as specifically called out in the
Purchase Order, the first day production test shall not be carried out. Pipes in such
case shall be accepted based on regular production tests.
The various tests to be conducted on each pipe shall be as follows. The test method
and acceptance values shall be as per this specification unless specified differently in
this Annexure.
a. Visual Examination
All pipes shall he examined visually for dimensional tolerances and apparent
surface defects.
b. Ultrasonic Examination
The weld seam of all pipes shall be examined ultrasonically by automatic
ultrasonic equipment.
c. Mechanical Properties
The mechanical properties of all pipes shall be tested and shall meet the
requirements of this specification. Purchaser Representative will select the places
in pipe from where the test specimen shall be removed.
The following tests shall be conducted:
i. 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:


- 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, +20°C for shear orp« t0 produce full transition curve. The
value at the test temperature specified in SR 6 of API Spec 5L duly modified in this
specification shall be complied with. For other temperatures, the value shall be for
information only
(Note: This test is to be carried out only when required as per para 6.2.5.3 of this
specification)
vi. Hardness test shall be conducted on selected pipes as per requirement of para
6.2.6 of this specification.
e. In addition, all the tests and inspections require to be conducted as per this
specification shall be conducted on all the pipes selected for testing during first day
production test.

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SPECIFICATION FOR ELECTRIC WELDED DOCUMENT No. REV-0
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SPECIFICATION FOR ELECTRIC WELDED DOCUMENT No. REV-0
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3-LAYER POLYETHYLENE COATING OF
LINEPIPES (ONSHORE)

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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 INSPECTION AND TESTING
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 : Specification for Line Pipe
w. ASME B31.8 : 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
(+)80°C, 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. Properties Unit Requirement Test Method

Melt Flow Rate g/10


a. 1 .0 min. ASTM D1238
(190°C/2.16kg) minutes
b. Vicat Softening Point °C 100 min. ASTM D1525
c. Specific Gravity - 0.926 min. ASTM D 792

5.3.2 Properties of Polyethylene Compound

SI. No. Properties Unit Requirement Test Method

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Tensile Strength
a. N/mm2 17 min. ASTM D 638
@ + 25° C

Melt Flow Rate 9/10 ASTM D 1238 or


b. 0.25 min.
(190DC/2.16kg) minutes DIN 53735

0.926 min.
Specific Gravity @ (MDPE)
c. - ASTM D 792
+ 25°C 0.941 min.
(HDPE)

d. Hardness @ + 25 °C Shore D 50 min. ASTM D 2240

Water Absorption, 24
e. % 0.05 max. ASTM D 570
hours, @ + 25 °C

Volume Resistivity @ +
f. Ohm-cm 1016min. ASTM D 257
25°C

Dielectric withstand,
g 1000 Volt/sec rise @ + Volts/ mm 30,000 min. ASTM D 149
25°C

h. Vicat Softening Point °C 110 min. ASTM D 1525

i. Elongation % 600 min. ASTM D 638


Oxidative
Induction Time in Oxygen
j- Minutes 10 ASTM D3895
at 220°C, Aluminum
pan, no screen

Environmental Stress
Crack Resistance
(ESCR) (for F 50) :
k. -Medium Density-
300
Condition "C”
Hours
-High Density- ASTM D1693
Condition "B"
300

l. Carbon Black Content % 2 min. ASTM D 1603

5.3.3 Properties of Coating System


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SI.
Properties Unit Requirement Test Method
No.

Bond Strength (using


Type 2 Test Assembly
8.0 min
a. i.e. Dynamometer) Kg/cm DIN 30670
5.0 min
. @20+/-5°C
. @65+/-5°C

Impact Strength
(Min. of 30 impacts on Joules per
b. body along the length. mm of coating 7 min DIN 30670
No breakdown allowed thickness
when tested at 25 Kv)

Indentation Hardness
0.2 max
c. @23+/-2°C mm DIN 30670
0.3 max
@70+/-2°C

d. Elongation at Failure % 300 min. DIN 30670

e. Coating Resistivity (*) Ohm - m2 10 8 min. DIN 30670

Melt Flow
Rate
shall not deviate
f. Heat Ageing (*) - DIN 30670
by more than
35% of original
value
Melt Flow
Rate shall not
9- Light Ageing (*) - deviate by more DIN 30670
than 35% of
regional value

Cathodic Disbondment
mm radius of 15 max.
@ + 65° C after 30
h. disbondment ASTM G42
days
(**)
@ + 65°C after 48 hrs
7 max.
Degree of Cure of
Epoxy. Percentage
Cure, ∆H. % 95 CSA Z
I 0
∆Tg C +3/-2 245.20-98(***)

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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 0°C. 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 65°C to 85°C 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 ISO-
11124
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
requirements of this specification.
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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 μmho/cm 5 max.

C Hardness - Nil

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 - 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 65°C to 85°C.
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 ½ 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 ½), 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 pre-
treatment solution is not permitted.
8.13.5 The CONTRACTOR shall ensure that the temperature of the substrate is maintained
between 40°C and 80°C and the chromate solution temperature does not exceed
60°C 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 190°Cor 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:

Minimum Coating
Pipe Size (Specified Outside Diameter) Thickness (mm)(*)
Normal Type Reinforced
(n) Type (v)
Up to 10 ¾ " (273.1 mm) 2.0 2.7
Over l0 ¾ (273.1 mm) to below 20" (508.0
2.2 2.9
mm)
From 20" (508.0mm) to below 32" (813.0
2.5 3.2
mm)

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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 (-)
40°C 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 INSPECTION AND TESTING


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 contractor’s 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 HANDLING, TRANSPORTATION AND STORAGE
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 (+)80°C 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 sub-
contractors 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 Adhesive PE Compound


(Manufacturer) (Manufacturer) (Manufacturer)

CORRO-COAT EP-F2001 FUSABOND158D SCLAIR 35 BP HDPE


(JOTUN) (DUPONT) (NOVACOR)

PE 50-8190/8191 (BASF) or LUCALEN G3510H LUPOLEN 3652 D SW


CORRO-COAT EP-F 2001 00413 (BASF)
(BASF)
(JOTUN)

PE 50-6109 (BASF) or ME 0420 (BORALIS) HE 3450 (BOREALIS)


CORRO-COAT EP-F
2001/2002HW (JOTUN) or
SCOTCHKOTE 226N (3M)

CORRO-COAT EP-F 2001 LE-149 V (S K ET 509 B (S K


(JOTUN) CORPORATION) CORPORATION)

SCOTCHKOTE 226N (3M) ME 0420 (BOREALIS) PB 48A004


(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

DOCUMENT No. REV-0


GAIL (INDIA) LTD SPECIFICATION FOR INTERNAL EPOXY
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CONTENTS
1 SCOPE
2 DEFINITIONS
3 ABBREVIATIONS
4 INTERNAL LIQUID EPOXY COATING
5 COATING MATERIAL
6 APPLICATION OF THE COATING MATERIAL
7 PRODUCTION CONTROL
8 REPAIRS
9 HANDLING, TRANSPORTATION AND STORAGE

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 : (NORMATIVE) CURING TEST (REFER TO SUB CLAUSE 7.2.5)

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

DOCUMENT No. REV-0


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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 - British Standards

DIN - 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