D 1 1

DATA SHEET NO.
DATA SHEET FOR

GLOBE VALVES A286-000-11-42-DS-0036 Rev. A
Page 1 of 1
Client : GIGL Dept. /Sect. : 11/42

Project :Mehsana-Bathinda Pipeline Project
Location : NA Tag No. : - Sheet No. 1 of 1
GLOBE VALVE SPECIFICATION MANUF'S OFFER
TAG NO. : - PIPING CLASS: D21A STANDARD :
BS EN ISO
RATING : 600 STANDARD : MFGRS CAT/FIG :
15761/API 602
FLGD TO B-16.5
SIZE RANGE : ½" TO 1½" ENDS : RATING : END :
RF/125 AARH
DESCRIPTION CONSTRUCTION MATERIAL CONSTRUCTION MATERIAL
SERVICE NATURAL GAS
Refer 6-44-0052 and Addendum to

TYPE OF
MANUAL Specification (Doc. No. A286-000-
OPERATOR
11-42-AD-0001)
VALVE BORE FULL BORE
TYPE OS & Y
CORROSION
1.5MM
ALLOWANCE
INSTALLATION ABOVE GROUND
ASTM A352 Gr. LCC/ ASTM A

BODY FORGED/ CAST
350 LF2 CL.1
ASTM A352 Gr. LCC/ ASTM A
BONNET WELDED
350 LF2 CL.1
SS304/ SS316 (NO CASTING) /
STEM (RISING) FORGED
17-4 PH (Stainless Steel)
DISC LOOSE PLUG TYPE STELLITED
RENEWABLE/ NON-
BODY SEAT RINGS STELLITED
RENEWABLE
CORROSION INHIBITED DIE
RENEWABLE WITH
FORMED FLEXIBLE
STEM PACKING VALVE OPEN ON
GRAPHITE WITH BRAIDED
STREAM
ANTI EXTRUSION RING
MALLEABLE IRON/ CAST
HAND WHEEL RISING STEEL/ DUCT IRON/
FABRICATED STEEL
BONNET BOLTS ASTM A 320 GR. L7
BONNET NUTS ASTM A 194 GR. 4 / Gr.7

SPECIAL SERVICE
CONDITION -45 DEG C FOR VALVE
(CHARPY)
HYDROSTATIC • BODY:153.41 BARG
TEST PRESSURE • SEAT:113.8 BARG
TEST PRESSURE
• 6 BARG
WITH AIR
NOTES:
1. The valve datasheet shall be read in conjunction with the technical notes for valves and
addendum to specification.
2. Testing shall be done as per BS EN – 12266 (Part-1 & 2).
A 07.09.12 Issued for Bids SYG SRG MSG

Rev Date Revisions By Chk Approved
Format No. EIL 1641-1924 Rev. 1
DATA SHEET NO.
DATA SHEET FOR
GLOBE VALVES A286-000-11-42-DS-0037 Rev. A
Page 1 of 1

GLOBE VALVE SPECIFICATION MANUF'S OFFER
RATING : 600 STANDARD : BS 1873 MFGRS CAT/FIG :
FLGD TO B-16.5
SIZE RANGE : 2" TO 12" ENDS : RATING : END :
RF/125 AARH
SERVICE NATURAL GAS
Refer 6-44-0052 and Addendum to

TYPE OF
MANUAL Specification (Doc. No. A286-000-11-
OPERATOR
42-AD-0001)
TYPE OS & Y
CORROSION
1.5 MM
ALLOWANCE
ASTM A352 Gr. LCC/ ASTM A 350
BODY FORGED/ CAST
LF2 CL.1
BONNET WELDED
LF2 CL.1
SS304/ SS316 (NO CASTING) / 17-4
STEM (RISING) FORGED
PH (Stainless Steel)
BODY SEAT RENEWABLE/

STELLITED
RINGS NON-RENEWABLE
CORROSION INHIBITED DIE
RENEWABLE
FORMED FLEXIBLE GRAPHITE
STEM PACKING WITH VALVE
WITH BRAIDED ANTI
OPEN ON STREAM
EXTRUSION RING
MALLEABLE IRON/ CAST STEEL/
HAND WHEEL RISING
DUCT IRON/ FABRICATED STEEL
BONNET BOLTS ASTM A 320 GR. L7
BONNET NUTS ASTM A 194 GR. 4 / Gr.7

SPECIAL SERVICE
CONDITION -45 DEG C FOR VALVE
(CHARPY)
TEST PRESSURE • 6 BARG
WITH AIR
NOTES:
1. The valve datasheet shall be read in conjunction with the technical notes for valves and
addendum to specification.
2. Testing shall be done as per BS EN – 12266 (Part-1 & 2).

DATA SHEET NO.
DATA SHEET FOR
CHECK VALVES A286-000-11-42-DS-0038Rev. A
Page 1 of 1

CHECK VALVE SPECIFICATION MANUF'S OFFER
RATING : 600 STANDARD : API 6D MFGRS CAT/FIG :
FLGD TO B-16.5
RF/125 AARH
SERVICE NATURAL GAS
Refer Spec. No. 6-71-0017 and

TYPE OF
MANUAL Addendum to Standard Specification
OPERATOR
(Doc. No. A286-000-11-42-AD-0001)
TYPE SWING CHECK TYPE
CORROSION
1.5 MM
ALLOWANCE
BODY FORGED/ CAST
LF2 CL.1
PRESSURE SEAL ASTM A352 Gr. LCC/ ASTM A 350
COVER
TYPE LF2 CL.1
BODY SEAT RENEWABLE/ NON-

STELLITED
RINGS RENEWABLE
DISC HINGE ASTM A 352 LCC/ SS 304/ SS316
HINGE PIN NO CASTING SS 304/ SS316
COVER GASKET SP-WND SS316-GRAFOIL FILTER
COVER STUD
ASTM A 320 GR. L7
BOLTS
COVER NUTS ASTM A 194 GR. 4 / Gr.7

SPECIAL SERVICE
CONDITION - 45 DEG C FOR VALVE
(CHARPY)
TEST PRESSURE 6 BARG
WITH AIR
NOTES:
1. The valve seat shall be non-renewable integral type only.
2. The valve body castings shall undergo 100% radiography.
3. Testing of the valve shall be done as per BS EN – 12266 (Part-1 & 2).

DATA SHEET NO.
DATA SHEET FOR
CHECK VALVES A286-000-11-42-DS-0039Rev. A
Page 1 of 1

CHECK VALVE SPECIFICATION MANUF'S OFFER
RATING : 600 STANDARD : API 6D MFGRS CAT/FIG :
FLGD TO B-16.5
RF/125 AARH
SERVICE NATURAL GAS
Refer Spec. No. 6-71-0017 and

TYPE OF
MANUAL Addendum to Standard Specification
OPERATOR
(Doc. No. A286-000-11-42-AD-0001)
SWING CHECK
TYPE
TYPE
CORROSION
1.5 MM
ALLOWANCE
BODY FORGED/ CAST
LF2 CL.1
PRESSURE SEAL ASTM A352 Gr. LCC/ ASTM A 350
COVER
TYPE LF2 CL.1
BODY SEAT RENEWABLE/

STELLITED
RINGS NON-RENEWABLE
DISC HINGE ASTM A 352 LCC/ SS 304/ SS316
HINGE PIN NO CASTING SS 304/ SS316
COVER GASKET SP-WND SS316-GRAFOIL FILTER
COVER STUD
ASTM A 320 GR. L7
BOLTS
COVER NUTS ASTM A 194 GR. 4 / Gr.7

SPECIAL SERVICE
CONDITION - 45 DEG C FOR VALVE
(CHARPY)
TEST PRESSURE 6 BARG
WITH AIR
NOTES:
1. The valve seat shall be non-renewable integral type only.
2. The valve body castings shall undergo 100% radiography.
3. Testing of the valve shall be done as per BS EN – 12266 (Part-1 & 2).

DATA SHEET No.
DATA SHEET FOR SCRAPER TRAP
(LAUNCHER / RECEIVER) A286-000-11-42-DS-43 Rev. B
Page 1 of 11
esglkukµHkfVaMk ikbiykbu ifj;¨tuk

MEHSANA – BATHINDA
PIPELINE PROJECT
(LAUNCHER/ RECEIVER)
B 06.09.12 REVISED & RE-ISSUED FOR BIDS SG SRG/ NR MSG
A 27.08.12 ISSUED FOR BIDS SG SRG/ NR MSG

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

DATA SHEET No.
Page 2 of 11
1. 36” OD MAINLINE (010-PL-00-101) DT PALANPUR & RT BATHINDA

PIPELINE DETAILS
Outside Diameter, mm (inch) 914.0 (36") Thickness, mm 19.1
Design Pressure (Barg) 98 Material API 5L Gr. X-70 PSL2
Design Temperature(°C) -20 to 65 Service Natural Gas
Design Code ASME B31.8 Design Factor 0.5
Corrosion Allowance, mm 0 mm ANSI Rating 600#
SCRAPER DETAILS (BI-DIRECTIONAL)
Design Code ASME B31.8, ASME Sec VIII Div I for QOEC
Scraper Trap Manufacturer -------
Scraper Trap Specification No. 6-71-0031 & A286-000-11-42-AD-0001
Type of Scraper Trap Scraper Launcher/Receiver suitable for Intelligent pigging
Corrosion Allowance 3.0 mm
Hydro test Pressure (Kg/cm2 g) 149.9 (for 15mins)
Charpy Impact Test as per clause 3.4 of Spec. No. 6-
Required
71-0031
Hardness Test as per clause 3.5 of Spec. No. 6-71-
Required
0031
Tag No. (s) 011-ML/MR-00-101, 022-MR/ML-00-101
OD in mm (inch)/
Part Material
Description Item Ends, Type Thk., in mm or
No. (Equivalent/ Superior)
Schedule
1016.0 (40")/ 23.8
1 Barrel Pipe BW, LSAW API 5L Gr. X-70 PSL-2
(Note-4)
Flanged, WNRF, 914.0 (36")/ 22.2
2 Neck Pipe API 5L Gr. X-70 PSL-2
(Note-4)
LSAW
MSS-SP-75 Gr. WPHY-70/ 1016.0 (40") x 914.0
3 Reducer Concentric BW, Welded ASTM A 860 Gr. WPHY-70 (36")
Kicker Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 323.9 (12.750”) / M,
4
connection + Pipe 600# ASTM A 333 Gr. 6 XXS / 17.5 (Pipe)
Bypass Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 323.9 (12.750”) / M,
5 ASTM A 333 Gr. 6 XXS / 17.5 (Pipe)
connection. + Pipe 600#
Drain Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 114.3 (4.5”) / M,
6 ASTM A 333 Gr. 6 XXS / S160 (Pipe)
connection + Pipe 600#
Utility Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 60.3 (2.375”) / M,
7
connection + Pipe 600# ASTM A 333 Gr. 6 XXS / S120 (Pipe)
Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/
8 PSV connection ‘HOLD’
+ Pipe 600# ASTM A 333 Gr. 6
Pressure Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 48.3 (1.5”) / XXS,
9 ASTM A 333 Gr. 6 XS (Pipe)
Indicator + Pipe 600#
Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 60.3 (2.375”) / M,
10 Vent ASTM A 333 Gr. 6 XXS / S120 (Pipe)
+ Pipe 600#
Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 60.3 (2.375”) / M,
11 Vent Bypass
+ Pipe 600# ASTM A 333 Gr. 6 XXS / S120 (Pipe)
12 Supports Plate Welded ASTM A 36 As required
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-70 1016.0 (40”) / 600#
14 Filtering Basket ASTM A 36

DATA SHEET No.
Page 3 of 11
2. 36” OD MAINLINE (010-PL-00-101) IP 01, IP 02, IP 03, IP 04 & IP 05
PIPELINE DETAILS
Required
71-0031
Required
0031
012-MR/ML-00-101 & 012- ML/MR-00-102
013-MR/ML-00-101 & 013- ML/MR-00-102
Tag No. (s) 015-MR/ML-00-101 & 015- ML/MR-00-102
018-MR/ML-00-101 & 018- ML/MR-00-102
020-MR/ML-00-101 & 020- ML/MR-00-102
OD in mm (inch)/
Part Material
Schedule
1016.0 (40")/ 23.8
(Note-4)
Flanged, 914.0 (36")/ 22.2
(Note-4)
WNRF, LSAW
MSS-SP-75 Gr. WPHY-70/ 1016.0 (40") x 914.0
3 Reducer Concentric BW, Welded ASTM A 860 Gr. WPHY-70 (36")
Kicker Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ API 406.4 (16”) / M, S80/
4
connection + Pipe WNRF, 600# 5L Gr. X-52 PSL 2 14.3 (Pipe)
Bypass Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ API 406.4 (16”) / M, S80/
5 5L Gr. X-52 PSL 2 14.3 (Pipe)
connection. + Pipe WNRF, 600#
Drain Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ 114.3 (4.5”) / M,
6 ASTM A 333 Gr. 6 XXS / S160 (Pipe)
connection + Pipe WNRF, 600#
Utility Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ 60.3 (2.375”) / M,
7
connection + Pipe WNRF, 600# ASTM A 333 Gr. 6 XXS / S120 (Pipe)
Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/
+ Pipe WNRF, 600# ASTM A 333 Gr. 6
Pressure Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ 48.3 (1.5”) / XXS,
9 ASTM A 333 Gr. 6 XS (Pipe)
Indicator + Pipe WNRF, 600#
Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ 60.3 (2.375”) / M,
10 Vent ASTM A 333 Gr. 6 XXS / S120 (Pipe)
+ Pipe WNRF, 600#
11 Vent Bypass
+ Pipe WNRF, 600# ASTM A 333 Gr. 6 XXS / S120 (Pipe)
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-70 1016.0 (40”) / 600#

DATA SHEET No.
Page 4 of 11
3. 24” OD CHITTORGARH SPURLINE (025-PL-00-104)
PIPELINE DETAILS
Type of Scraper Trap Scraper Launcher/Receiver suitable for intelligent pigging
Required
71-0031
Required
0031
Tag No. (s) 025- ML/MR-00-101 & 027-MR/ML-00-101
OD in mm (inch)/
Part Material
Schedule
711.0 (28")/ 17.5
(Note-4)
Flanged, 610.0 (24")/ 15.9
WNRF, LSAW (Note-4)
MSS-SP-75 Gr. WPHY-70/ 711.0 (28") x 610.0
3 Reducer Concentric BW, Welded ASTM A 860 Gr. WPHY-70 (24")/
Kicker Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ 219.1 (8.625”) / M,
4 ASTM A 333 GR. 6 XXS/ XS (Pipe)
Bypass Weldolet + Flange Flanged, ASTM A 350 Gr. LF 2/ 219.1 (8.625”) / M,
5
connection. + Pipe WNRF, 600# ASTM A 333 GR. 6 XXS/ XS (Pipe)
6
connection + Pipe WNRF, 600# ASTM A 333 GR. 6 XXS / S160 (Pipe)
7 ASTM A 333 GR. 6 XXS / S120 (Pipe)
8 PSV connection ASTM A 333 GR. 6
‘HOLD’
+ Pipe WNRF, 600#
9
Indicator + Pipe WNRF, 600# ASTM A 333 GR. 6 XS (Pipe)
10 Vent
+ Pipe WNRF, 600# ASTM A 333 GR. 6 XXS / S120 (Pipe)
11 Vent Bypass ASTM A 333 GR. 6 XXS / S120 (Pipe)
+ Pipe WNRF, 600#
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-70 711.0 (28")/ 600#

DATA SHEET No.
Page 5 of 11
4. 12” NB SPURLINES UDAIPUR (037-PL-00-102), HISSAR (038-PL-00-112) & JODHPUR (014-PL-00-105)
PIPELINE DETAILS
Outside Diameter, mm (inch) 323.9 (12.750") Thickness, mm 7.9
Required
71-0031
Required
0031
027- ML/MR-00-101 & 024-MR/ML-00-101
Tag No. (s) 014- ML/MR-00-101 & 028-MR/ML-00-101
038- ML/MR-00-101 & 039-MR/ML-00-101
OD in mm (inch)/
Part Material
Schedule
406.4 (16")/ 12.7
1 Barrel Pipe BW, ERW API 5L Gr. X-65 PSL-2
(Note-4)
Flanged, 323.9 (12.750")/
WNRF, ERW 11.1 (Note-4)
406.4 (16")/x 323.9
3 Reducer Concentric BW, Welded MSS-SP-75 Gr. WPHY-65
(12.750")
4 XXS / S160 (Pipe)
connection + Pipe WNRF, 600# ASTM A 333 GR. 6
5 XXS / S160 (Pipe)
connection. + Pipe WNRF, 600# ASTM A 333 GR. 6
6
7
+ Pipe WNRF, 600# ASTM A 333 GR. 6
9 XS (Pipe)
Indicator + Pipe WNRF, 600# ASTM A 333 GR. 6
10 Vent
11 Vent Bypass
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-65 406.4 (16")/ 600#

DATA SHEET No.
Page 6 of 11
5. 18” NB BHIWADI SPURLINE (017-PL-00-107)
PIPELINE DETAILS
Outside Diameter, mm (inch) 457 (18") Thickness, mm 10.3
SCRAPER DETAILS (BI- DIRECTIONAL)
Required
71-0031
Required
0031
017- ML/MR-00-101& 030-MR/ML-00-101
Tag No. (s)
030- ML/MR-00-102& 032-MR/ML-00-101
OD in mm (inch)/
Part Material
Schedule
610 (24")/ 17.5
(Note-4)
Flanged, 457 (18")/
WNRF, LSAW 14.3(Note-4)
610 (24") x 457
(18")
4
5
connection. + Pipe WNRF, 600# ASTM A 333 GR. 6 XXS / S120 (Pipe)
6 XXS / S160 (Pipe)
7 XXS / S120 (Pipe)
9
Indicator + Pipe WNRF, 600# ASTM A 333 GR. 6 XS (Pipe)
10 Vent XXS / S120 (Pipe)
11 Vent Bypass XXS / S120 (Pipe)
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-65 610 (24")/ 600#

DATA SHEET No.
Page 7 of 11
6. 8” NB ALWAR SPURLINE (031-PL-00-108)
PIPELINE DETAILS
Outside Diameter, mm (inch) 219.1 (8.625") Thickness, mm 6.4
Required
71-0031
Required
0031
Tag No. (s) 031- ML/MR-00-101 & 033-MR/ML-00-101
OD in mm (inch)/
Part Material
Schedule
323.9 (12.750")/
12.7 (Note-4)
Flanged, 219.1 (8.625")/
WNRF, ERW 9.5(Note-4)
323.9 (12.750")x
219.1 (8.625")
4 XXS / S160 (Pipe)
5 XXS / S160 (Pipe)
connection. + Pipe WNRF, 600# ASTM A 333 GR. 6
6
7 XXS / S120 (Pipe)
9 XS (Pipe)
10 Vent
11 Vent Bypass
323.9 (12.750")/
13 End Closure Forged Quick Opening ASTM A 350 Gr. LF2
600#

DATA SHEET No.
Page 8 of 11
7. 18” NB ROHTAK SPURLINE (019-PL-00-109)
PIPELINE DETAILS
Required
71-0031
Required
0031
Tag No. (s) 019- ML/MR-00-101& 034-MR/ML-00-101
OD in mm (inch)/
Part Material
Schedule
610 (24")/ 17.5
(Note-4)
Flanged, 457 (18")/
WNRF, ERW 14.3(Note-4)
614 (24") x 457
(18")
4
5
6
7 XXS / S120 (Pipe)
Pressure Weldolet + Flange Flanged, WNRF, ASTM A 350 Gr. LF 2/ 48.3 (1.5”) / XXS,
9 XS (Pipe)
Indicator + Pipe 600# ASTM A 333 GR. 6
10 Vent
11 Vent Bypass
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-65 610 (24”)/ 600#

DATA SHEET No.
Page 9 of 11
8. 18” NB GGSRL SPURLINE (021-PL-00-111)
PIPELINE DETAILS
Required
71-0031
Required
0031
Tag No. (s) 021- ML/MR-00-101 & 036-MR/ML-00-101
OD in mm (inch)/
Part Material
Schedule
610 (24")/ 17.5
(Note-4)
Flanged, 457 (18")/
WNRF, LSAW 14.3(Note-4)
610 (24") x 457
(18")
4
5
6 XXS / S160 (Pipe)
7
9 XS (Pipe)
10 Vent XXS / S120 (Pipe)
11 Vent Bypass
13 End Closure Forged Quick Opening ASTM A 694 Gr. F-65 610 (24”)/ 600#

DATA SHEET No.
Page 10 of 11
A B C D E
14 3 2
I J K L
M
4 1 5
13 8 9 10 PLAN 11
H
H
F G
1 Barrel 8 Pressure Relief Valve

2 Neck 9 Pressure Indicator
3 Conc. Reducer 10 Vent
4 Kicker Connection 11 Vent Bypass
5 By Pass Connection 12 Support
6 Drain Connection 13 End Closure
7 UC 14 Filtering Basket
Pipeline
Size
A B C D E F G H I J K L M N
(NB)
Inch
As per
36” 700 2300 500 610 3300 500 500 500 1000 500
Std.
As per
30” 700 1800 500 610 3000 500 500 500 1000 500
Std.
As per
24” 700 1800 500 610 3000 500 500 500 1000 500
Std.
By By By As per
18” 700 1600 500 508 2800 500 500 500 1000 500
Vendor Vendor Vendor Std.
As per
12” 700 1600 500 356 2800 500 500 500 1000 500
Std.
As per
10” 700 1400 500 330 2600 500 500 500 1000 500
Std.
As per
8” 700 1400 500 203 2600 500 500 500 1000 500
Std.

DATA SHEET No.
Page 11 of 11
NOTES:
1. All requirements applicable for gas service shall be complied with as per specification no. 6-71-0031.
2. The dimensions indicated above are suggested dimensions only. The Vendor/ Manufacturer shall check
and provide dimensions suitable for accommodating latest online inspection tool (longest). Final
dimensions shall be approved by Company.
3. Orientation of all the nozzles is indicative and shall be confirmed during Detailed Engineering
4. Indicated wall thicknesses for body & neck are minimum. Manufacturer shall check the same based on
pipeline design conditions and manufacturing requirements, and submit necessary calculations to
Company for approval.
5. Flanges welded on Scraper trap shall have smooth face finish to 125 - 250 AARH.
6. The Charpy V-notch test requirements of applicable LTCS material standard shall be conducted.
In addition to above the Charpy V-notch test shall be conducted at -20°C. Test procedure shall conform
to ASTM A 370. The average absorbed energy value of full sized specimens shall be as per 35 J. The
minimum impact energy value of specimen analysed as above, shall not be less than 28J.
7. Scraper trap shall be provided with suitable handling system for retraction, insertion & launching of pigs
including instrumented pigs (such as basket / tray; retracting rod/ mechanism etc.) from the trap as per
drawing no. A286-000-11-42-3042 and clause 4.11 of specification no. 6-71-0031. Price of scraper trap
shall be inclusive of pig handling system. However, pig lifting devices (davit etc.) are not in Vendor’s
scope of supply.
8. Manufacturer shall ensure that the wall thickness (W.T.) of all parts of flow tee shall be adequate to
sustain design pressure and selected W.T. shall be suitable for welding with W.T. of connecting pipeline/
piping.
9. All carbon steel fittings/flanges made from ASTM A350 LF2 material shall be heat treated by
normalizing in accordance with ASTM A961. All carbon steel fittings and flanges made from ASTM
A350 LF2 material shall be finish forged i.e. forged to the required shape. Machined fittings and flanges
are not acceptable. Machining is permitted for weld end preparation and flange face finish preparation.
10. All Weldolet and Sockolet shall be as per MSS-SP-97
11. Dimensions for 36” flange shall be as per ASME B16.47 Series ‘A’, for other flanges dimensions shall
be as per ASME B 16.5.
12. Material Compliance as per EN 10204 3.2 Certificate.
13. Manufacturer shall carry out PWHT wherever applicable (if required).
14. The surfaces shall be cleaned to SA 2½ (in accordance with ISO 8502-3) using suitable grit/shot blasting
free of any deterious contamination or moisture. The surface roughness shall be checked at random and
shall be for the range of 50-70 microns in accordance with ISO 4287-1.
15. The painting shall be carried out as per Spec No. 6-44-0004. Final DFT thickness shall be as per Table
6.2.
16. These dimensions shall be decided by Manufacturer and approved by Company.

DATA SHEET No.
DATA SHEET FOR PIG SIGNALLER
(NON-INTRUSIVE TYPE) A286-000-11-42-DS-0045 Rev. A
Page 1 of 16
Pig Signaller (Non Intrusive Type) - Universal Clamp-On type mounted on 36” Line Size
Pig Signaller Manufacturer
011-XXS-1112 , 012-XXS-1213 , 012-XXS-1214

013-XXS-1311 , 013-XXS-1312 , 015-XXS-1511
Pig Signaller Tag No.
015- XXS-1512 , 018-XXS-1811 ,018-XXS-1812
020-XXS-2011 , 020-XXS-2012 , 022-XXS-2211
Purchaser’s Specifications A286-000-11-42-SP-0033
General
Service Natural Gas
Area Classification Zone 2,Gr. IIA/ IIB, T3

A286-04-41-011-1111, A286-04-41-012-1112
A286-04-41-013-1113, A286-04-41-015-1115
P&ID Number
A286-04-41-018-1118, A286-04-41-020-1120
A286-04-41-022-1122
Line Size (Inch) 914 mm (36” )
Pig Detection At Passage
Process Data
Fluid State Gas
Viscosity (cP) 0.011-0.012
Density (kg/m³) 6-90

-20 to +60 (Under Ground)
Design Temperature, (°C)
-20 to +65 (Above Ground)
Operating Temperature, (°C) 55-27 0C
Design Pressure kg/cm2, (barg) 99.93 (98 barg)
Operating Pressure kg/cm2, (barg) 96.8 (95 barg)
Multiphase Product (Yes / No) No
A 23.08.2012 Issued for Bids SG SRG/ NR MSG

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATA SHEET No.
Page 2 of 16
Sensing Element
Type Non-intrusive (Bi-directional)
Sensor Element Piezo electrical crystal
Sensor repeatability 1% Minimum
Detection Passive acoustics based (Ultrasonic type)
Connection Universal Clamp-on type
Self testing capability Required
Detection Speed By Vendor
1 No. Potential free contact (DPDT), 1 No Serial
Signal Output Communication Interface ( Modbus over RS-485 /
Ethernet)
Particle & Pig Detection Required
Spectrum analysis using associated software Required
Enclosure
Body Material AISI SS316L
Internals Note - 2
Degree of Protection EEx 'd', IP 65
Power Supply 24 VDC+ 10%
Signal Interface To RTU
Electrical Entry 1/2” NPTF(Note-3)
Pipeline Specification
Pipeline Diameter (NB) 914 mm (36”)
Pipeline wall thickness (mm) 19.1 mm
Pipeline wall Material API 5L Gr. X-70 PSL-2
Pipeline Coating (Internal) Epoxy Paint (DFT 110+10 microns)
Pipeline Coating (External) 3 Layer Polyethylene (3.55 mm Min)
Horizontal
Orientation of Pipe (Horizontal / Vertical)

DATA SHEET No.
Page 3 of 16
Pig Details
Pig Material Carbon Steel
Pig Length 600 mm ~ 3000 mm (Indicative)
Pig Diameter (O. D.) 95% ~ 100 % of Pipeline ID
Pig Velocity (Max. / Normal) 8 m/Sec
Others
Red LED based, EExe, IIB, T5, IP65 (visible from
Local Indicator
min. 5 Mtrs)
Local Reset Button Black Colour, Eexd, IP65
Data Storage Capacity Up to 60 days of measurement data
Inbuilt Battery Required
Termination Junction Box Required (Note-8)
Bolting Material ASTM A 193 Gr.B7M / ASTM A194 Gr. 2HM

DATA SHEET No.
Page 4 of 16
025-XXS-2512, 027-XXS-2712

General
Service Natural Gas
P&ID Number A286-04-41-025-1125, A286-04-41-027-1127

Process Data
Fluid State Gas


DATA SHEET No.
Page 5 of 16
Sensing Element
Ethernet)
Enclosure
Internals Note - 2
Horizontal

DATA SHEET No.
Page 6 of 16
Pig Details
Others
Local Indicator
min. 5 Mtrs)

DATA SHEET No.
Page 7 of 16
017-XXS-1712 , 019-XXS-1912 , 021-XXS-2112

Pig Signaller Tag No. 030-XXS-3013 , 030-XXS-3014 , 032-XXS-3212
034-XXS-3412 , 036-XXS-3612

General
Service Natural Gas

A286-04-41-017-1117, A286-04-41-019-1119
A286-04-41-021-1121, A286-04-41-030-1130
P&ID Number
A286-04-41-032-1132, A286-04-41-034-1134
A286-04-41-036-1136
Process Data
Fluid State Gas


DATA SHEET No.
Page 8 of 16
Sensing Element
Ethernet)
Enclosure
Internals Note - 2
Horizontal

DATA SHEET No.
Page 9 of 16
Pig Details
Others
Local Indicator
min. 5 Mtrs)

DATA SHEET No.
Page 10 of 16
014-XXS-1412 , 024-XXS-2412 , 027-XXS-2722

028-XXS-2812 , 038-XXS-3812 , 038-XXS-3912

General
Service Natural Gas

A286-04-41-014-1114, A286-04-41-024-1124
P&ID Number A286-04-41-027-1127, A286-04-41-028-1128
A286-04-41-038-1138, A286-04-41-039-1139
Line Size (Inch) 323.9 mm (12” )
Process Data
Fluid State Gas


DATA SHEET No.
Page 11 of 16
Sensing Element
Ethernet)
Enclosure
Internals Note - 2
Pipeline Diameter (NB) 323.9 mm (12”)
Horizontal

DATA SHEET No.
Page 12 of 16
Pig Details
Others
Local Indicator
min. 5 Mtrs)

DATA SHEET No.
Page 13 of 16
016-XXS-1612 , 023-XXS-2312 , 026-XXS-2612

029-XXS-2912 , 031-XXS-3112 , 033-XXS-3312

General
Service Natural Gas

A286-04-41-016-1116, A286-04-41-023-1123
P&ID Number A286-04-41-026-1126, A286-04-41-029-1129
A286-04-41-031-1131, A286-04-41-033-1133
Line Size (Inch) 219.1 mm (8” )
Process Data
Fluid State Gas


DATA SHEET No.
Page 14 of 16
Sensing Element
Ethernet)
Enclosure
Internals Note - 2
Pipeline Diameter (NB) 219.1 mm (8”)
Horizontal

DATA SHEET No.
Page 15 of 16
Pig Details
Others
Local Indicator
min. 5 Mtrs)

DATA SHEET No.
Page 16 of 16
Notes:
1. All field electronic shall be sealed in an epoxy resin for protection.
2. All Pig Signallers shall have two (2) nos. of inbuilt batteries (1 working + 1 spare), with a
minimum lifespan of 1 year.
3. Four Nos. ½” NPTF cable gland entries are to be provided. One (1) nos. for signal, One
(1) nos. for power, One (1) for Communication and one (1) nos. as a spare. All entries
shall be supplied with suitably EEx'd' entry plugs.
4. All cable glands supplied by the Vendor shall be EExe/EExd certified double
compression type with PVC shrouds.
5. The Pig Signaller shall be capable of detecting all type of pigging devices (permanent
magnet type and transmitter equipped intelligent pigs).
6. The Pig Signaller / detectors sensor is mounted in hermetically sealed AISI SS316L
housing and to be clamped to the external surface of the pipe or the launcher's /
receivers minor chamber through which the pig is passing.
7. Vendor to provide sensor cable between sensor & termination junction box.
8. Termination junction boxes of AISI SS316L material and certified as EExe IIB, IP-65
minimum shall be provided for connecting the sensor cables to the power and signal
cables, the light indication and reset switch. Termination box of Eexd type suitble for
hazardous area classification.
9. Vendor to provide all necessary mounting accessories for installation of scraper

signaller.
10. The total weight of Pig Signaler assembly should not exceed 10.0 Kg.
11. Area Classification: IEC Zone-2, IIA/IIB, T3.
12. Signal Output: Contact output - 1 NO and 1 NC (DPDT) potential free.
13. Signal interface: Local panel through contact output to be consider apart from RTU.
14. Cable entry Power/Signal: 1 Nos. power ½” NPTF / 3 Nos. Signal ½” NPTF.
15. Local indicator shall be Eexd type.

DATA SHEET NO.
DATA SHEET FOR FLOW TEE A286-000-11-42-DS-46 Rev. B
Page 1 of 4

PIPELINE PROJECT
DATA SHEET FOR FLOW TEE

DATA SHEET NO.
DATA SHEET FOR FLOW TEE A286-000-11-42-DS-46 Rev. B
Page 2 of 4
c c
Flow Tee Manufacturer ----

Purchaser’s Specifications no. 6-71-0025
DESIGN DATA
Service Natural Gas
• ASME B 31.8/ B 16.25 / B16.9 for Tee &
Internal Sleeves (up to NPS 14 and
smaller size).
Design Code • ASME B 31.8/ B 16.25 / MSS SP 75 for
Tee & Internal Sleeves (NPS 16 and larger
size).
• ASME Sec VIII Div I for End Piece.
Design Pressure (barg) 98
-20 to 65 (Above Ground)
Design Temperature (°C)
-20 to 60 (Under Ground)
ANSI Rating 600#
3.0 mm for End Piece.
Corrosion Allowance (mm)
1.5 mm for Tee & Internal Sleeves
Design Factor (F) 0.5
Hydrostatic Test Pressure (barg) 147 (For 15 Mins)
For all types of Pigs (including Intelligent
Suitability of Flow Tee
Pigs)/ Spheres
Flow Direction Bi-directional
Charpy Impact Test Refer Note 4
Hardness Test Required as per Spec
Installation Above Ground and under Ground (Note 5)
Format No. EIL 1641-1924 Rev. 1 A286-000-11-42-DS-0046 Rev B Flow Tee

DATA SHEET NO.
DATA SHEET FOR FLOW TEE A286-000-11-42-DS-46 Rev. A
Page 3 of 4
RUN PIPE BRANCH PIPE FLOW TEE MATERIAL

SR Part No.
SIZE Thickness Thickness Part No. 1 Part No. 3
NO Outside Outside 2
(mm)/ (mm)/
Diameter, Material Diameter, Material
Schedule Schedule, End Internal
D1 (mm) D2 (mm) Tee
T1 T2 Pieces Sleeve
API 5L Gr. API 5L Gr. MSS SP-75, Gr.
ASTM A 694 API 5L Gr. B
1. 36” x 36” 914 19.1 X-70, PSL - 914 20.6 X-70, WPHY-70/ ASTM
Gr. F 70 PSL-2
2 PSL -2 A 860 WPHY 70
2. 36” x 24” 914 19.1 X-70, PSL - 610 19.1 X-52, WPHY 70/ ASTM
Gr. F-70 PSL-2
2 PSL -2 A 860 WPHY 70
3. 36” x 18” 914 19.1 X-70, PSL - 457 15.9 X-52, WPHY-70/ ASTM
Gr. F-70 PSL-2
2 PSL -2 A 860 WPHY 70
MSS SP-75, Gr.
24” x API 5L Gr. X- ASTM A ASTM A 694 API 5L Gr. B
4. 610 12.7 323.9 17.5 WPHY-52/ ASTM
12.750” 70, PSL -2 333 Gr.6 Gr. F-70 PSL-2
A 860 WPHY 52
MSS SP-75, Gr.
5. 457 10.3 323.9 17.5 WPHY-52/ ASTM
12.750” 65, PSL -2 333 Gr.6 Gr. F-65 PSL-2
A 860 WPHY 52
MSS SP-75, Gr.
6. 457 10.3 219.1 XS WPHY-52/ ASTM
8.625” 65, PSL -2 333 Gr. 6 Gr. F-65 PSL-2
A 860 WPHY 52
12.750” x API 5L Gr. X- ASTM A ASTM A 420 ASTM A 694 API 5L Gr. B
7. 323.9 7.9 168.3 S120
6.625” 65, PSL -2 333 Gr 6 WPL 6 Gr. F-65 PSL-2
8.625” x API 5L Gr. X- ASTM A ASTM A 420 ASTM A 694 API 5L Gr. B
8. 219.1 6.4 114.3 S160
4.5” 52, PSL -2 333 Gr 6 WPL 6 Gr. F-52 PSL-2
Format No. EIL 1641-1924 Rev. 1 A286-000-11-42-DS-0046 Rev B Flow Tee Copyright EIL – All rights reserved
DATA SHEET No.
DATA SHEET FOR FLOW TEE A286-000-11-42-DS-46 Rev. A
Page 4 of 4
Notes:
1. Manufacturer to indicate dimensions A, B, C, T1 and T2 marked in the Sketch on

page 2 of 5.
2. Holes/ slots in the sleeve shall be arranged at 450 to the centre line of Flow Tee.
Manufacturer shall furnish details of holes/ slots in internal sleeve. The area of the
holes shall be minimum equal to the internal area of branch pipe. Relevant
calculation to this extent shall be furnished.
3. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at pipe end) tolerance shall be as per the following table :
8” and below = 2mm
10” to 16” = 3mm
18” and above = 4mm
4. The Charpy V-notch test requirements of applicable LTCS material standard shall be
conducted.
In addition to above the Charpy V-notch test shall be conducted at -20°C. Test
procedure shall conform to ASTM A 370. The average absorbed energy value of full
sized specimens shall be as per 35 J. The minimum impact energy value of specimen
analysed as above, shall not be less than 27J.
5. Manufacturer shall ensure that the wall thickness (W.T.) of all parts of flow tee shall
be adequate to sustain design pressure and selected W.T. shall be suitable for
welding with W.T. of connecting pipeline/ piping.
6. Flow tee to be installed underground shall be coated with 300 micron thick PU/ High
build epoxy coating.
8. Manufacturer shall carry out PWHT wherever applicable (if required).
9. The surfaces shall be cleaned to SA 2½ (in accordance with ISO 8502-3) using
suitable grit/shot blasting free of any deterious contamination or moisture. The
surface roughness shall be checked at random and shall be for the range of 50-70
microns in accordance with ISO 4287-1.
10. The painting shall be carried out as per Spec No. 6-44-0004. Final DFT thickness
shall be as per Table 6.2.
11. The internal surface of Flow Tees shall be Ultrasonically Tested.
DATA SHEET NO.
DATA SHEET FOR
INSULATING JOINT A286-000-11-42-DS-0047 Rev B
Page 1 of 6
DATA SHEET FOR PIPELINE INSULATING JOINT (For 36 Inch)

Insulating Joint Manufacturer -----
EIL Specifications 6-71-0026
DESIGN DATA
Service Natural Gas
Size (OD), mm (inch) 914 (36”)
Quantity (Nos.) 12 (Twelve)
Design Pressure, bar (g) 98
ANSI Rating 600#
Design Temperature (°C) -20 to + 65
Corrosion Allowance (mm) 1.5
Hydrostatic Test Pressure, bar (g) 147 (For 15 Mins)
Design Code (Pipeline / Insulating Joint) ASME B31.8 / ASME SEC. VIII DIV. I
End Connection Butt weld ends
Installation Above ground
Charpy Impact Test Refer Note-4
Hardness Test Required as per specification
INSULATING JOINT MATERIAL (EQUIVALENT OR SUPERIOR)
Material of Construction
Part
Specified Offered
MSS-SP-75 WPHY Gr.70/
Body
ASTM A 694 Gr. F-70
Pups API 5L Gr.X-70 PSL-2 (Note-1)
As per Manufacturer’s standard
Insulation
(Note-5)
CONNECTING PIPE DETAILS
S. No. Outside Diameter, OD mm (inch) Wall Thickness, mm Material

1. 914 (36”) 19.1 API 5L Gr.X-70 PSL-2
B 24.08.2012 Revised & Re-Issued for Bids SG SRG MSG
A 09.08.2012 Issued for Bids SG AA/NR MSG
DOCUMENT No.
DATA SHEET FOR
Page 2 of 6

DESIGN DATA
Service Natural Gas
Quantity (Nos.) 2 (Two)
ANSI Rating 600#
Hydrostatic Test Pressure, bar (g) 147 (For 15 Mins.)
Part
Specified Offered
Body
ASTM A 694 Gr. F-70
Insulation
(Note-5)

1. 610 (24”) 12.7 API 5L Gr.X-70 PSL-2
DOCUMENT No.
DATA SHEET FOR
Page 3 of 6

DESIGN DATA
Service Natural Gas
Quantity (Nos.) 8 (Eight)
ANSI Rating 600#
Part
Specified Offered
Body
ASTM A 694 Gr. F-65
Insulation
(Note-5)

1. 457 (18”) 10.3 API 5L Gr.X-65 PSL-2
DOCUMENT No.
DATA SHEET FOR
Page 4 of 6

DESIGN DATA
Service Natural Gas
Size (OD), mm (inch) 323.9 (12”)
Quantity (Nos.) 4 (Four)
ANSI Rating 600#
Part
Specified Offered
Body
ASTM A 694 Gr. F-65
Insulation
(Note-5)

1. 323.9 (12”) 7.9 API 5L Gr.X-65 PSL-2
DOCUMENT No.
DATA SHEET FOR
Page 5 of 6

DESIGN DATA
Service Natural Gas
Size (OD), mm (inch) 219.1 (8”)
Quantity (Nos.) 6 (Six)
ANSI Rating 600#
Part
Specified Offered
Body
ASTM A 694 Gr. F-52
Insulation
(Note-5)

1. 219.1 (8”) 6.4 API 5L Gr.X-52 PSL-2
DOCUMENT No.
DATA SHEET FOR
Page 6 of 6
Notes:
1. The pup piece shall be conforming to Spec. No. A286-000-11-42-SP-

0001(LSAW)/0005(ERW) and complying all chemical and mechanical testing
requirement as per Spec. No. A286-000-11-42-SP-0001(LSAW)/0005(ERW) enclosed
in the bid package.
2. For the welding end, the out of roundness (i.e. difference between maximum and
minimum ID at pipe end) tolerance shall be as per the following table :
8” and below = 2mm
10” to 16” = 3mm
18” and above = 4mm.
3. Manufacturer shall ensure that the wall thickness (W.T.) of all parts of insulating joint
shall be adequate to sustain design pressure and selected W.T. shall be suitable for
welding with W.T. of connected pipeline.
4. The Charpy V-notch test shall be conducted at -20°C. Test procedure shall conform to
ASTM A 370. The average absorbed energy value of full sized specimens shall be 35
J. The minimum impact energy value of specimen analysed as above, shall not be less
than 28 J.
5. Insulating material shall meet requirement of clause 4.3 of EIL Spec. 6-71-0026.
7. Manufacturer shall carry out performance test such Fatigue Test, Holiday Test (2.5
KV), Adhesion test (for External Coating), Pneumatic Test (5 bar for 10 Mins.).
8. The painting shall be carried out as per Spec No. 6-44-0004. Final DFT thickness shall
be as per Table 6.2.
Limit Switches
GENERAL CERTIFICATES
1. Type:- Proximity type switches as per DIN 19234 16. Statutory : CCOE
2. Mounting :- On valve 17. Others :
3. Area Classification :- Zone-1, IIA/IIB,T3
SWITCH OTHERS
4. Hysterisis : * 18. Model : *
5.Form : Proximity 19. Make : *
6. Enclosure Type : IP 65
7. Type of Protection : Intrinsicaly safe
8. Power : 24 VDC
9. Contact rating : *
10.Cable entry power:1/2" NPTF Signal : 1/2"NPTF
OPTIONS
11. IS Barrier : Not Required Type: NA
12. Switching amplifier :
Type. :-
Rating :-
13. Contact status before actuation
14. Contact status after actuation
15. Mounting accessories : Requir
NOTES:-
1. Quantity and Tag No shall be as per individual valve data sheet
2. Vendor shall provide separate switches for Open and Close positions
3. For cable connection flying leads are not to be used. Suitable terminal blocks/ enclosure suitable for hazardous area classification Zone-1, IIA/IIB
T3 shall be provided for cable termination
4. The limit switches shall be intrinsically safe type and weather proof to IP 65. Certificates to this effect indicating entity parameters shall be
furnished from statutory body
5. Limit switches shall be inductive proximity type and shall meet NAMUR (DIN19234) requirement
6. CCOE certificate shall be furnished for specified area classification
* By Vendor
DEVIATION NO DEVIATION VENDORS' SIGNATURE WITH SEAL
VENDOR DRAWING NO:- ORDER NO:-
FILE: REQUISITION NO : 16.08.12 AB AR AR

CLIENT : GIGL DATE BY CHKD APPD
ENGINEERS INDIA LIMITED
R.O CHENNAI PLANT : MBPL Unit: DATA SHEET NO. REV
VENDOR : A286-000-YI-DS-7001 A
This drawing and the design it covers are the properties ofENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will
not be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower
Data Sheet_Limit Switches.xls,sheet1

Differential Pressure Switches
UNITS: Flow->Liquid- Gas- Steam- Pressure-> Temperature->°C Level / Length-> mm
1. Type:- Snap Acting sealed micro type 10. Set Point Adjustment :- Required
2. Mounting :- Integral mounted on GOOV 11. Differential :- Note-5
3. Dial : 12. Scale Accuracy :- ± 5% of set value
Size :-
Colour :- 13. Repeatability :- ± 1% of set range
4. Case Matl :- Mettalic ( Mfr. Standard) MEASURING UNIT
5. Window matl. :- 14. Element Type :- Diaphragm
6. Area Classification :-IEC Zone-2, IIA/IIB,T3 15. Element Material :-SS316
7. Intrinsically Safe :- Required as per haradous area 16. Process Connection :- 1/2" NPT
8. Enclosure : 17. Diaphragm Seal :
Type :- Weather proof Type :-
Class :- IP 65 Wetted Part Matl.:-
Others Matl. :-
Process Conn.:Size & Rating :-
SWITCH Facing & Finish :-
Armour Flexible : -
9. Output.: Armour Material :-
Electric Contact :- Capillary Material :-
Qty. :- One NO/One NC( DPDT) Capillary Length :-
Form :- * 18. Over Range Protection : Note-3
Type :- *
Contact Plating :- Suitable for intrinsically safe application
Rating :- 2A, 24 VDC 19. Blow Out Protection :-
Load Type :- *
Cable Entry :- 1/2" NPTF 20. Mounting Accessories :-
No. of Entries :- Two. One entry plugged with WP plug
Pneumatic : On- Off :- 21. Options :
Type :- a ) Snubber
Air Supply b ) Gauge saver
Signal :- c ) Air Filter Regulator
Pneumatic Connection.:- d ) Mount. Acc. For 2" pipe
e)
SET POINT PRESSURE TEMPERATURE ° C
Tag Number RANGE SERVICE OPTIONS
1 2 OPER. MAX. OPER. MAX.
NOTES:-
1. Pressure sensing element shall be either diaphragm or bellow with SS316 material of construction as minimum suitable for process condition specified.
2. Pressure switch construction shall ensure no leakage of process fluid to atmosphere, high pressure and low presuure side under normal condition.
3. Switch shall be micro sealed type with suiatble rating. Over range protection shall be 130% of maximum working pressure as minimum.
4. Set point shall fall in the middle 30% of full adjustable range i.e. set point fall between 35% and 65% of adjustable range in general.
5. In general differential shall be such that reset pressure is 10% below the set pressure.
6. The Tag Nos. Set point , range , other details and data sheet number shall be provided by contractor based on valve tag nos for this project
and furnished for review
7. Set point shall be field adjustable and indicating sacle shall be provieded for adjustment. Locking mechanism shall be provided for set point
adjuster. Whenever maximum pressure specified exceeds over range protection pressure, over range protector shall be provided.
*: By Vendor
VENDOR DRAWING NO:- ORDER NO:-
FILE: REQUISITION NO :
CLIENT : DATE BY CHKD APPD

ENGINEERS INDIA LIMITED DATA SHEET NO. REV
PLANT : Unit - 000
VENDOR : A286-000-YP-DS-3500 0
Diff.Pressure Switches_data sheet.xls

SPECIFICATION FOR DOCUMENT No.
LONGITUDINAL SEAM SUBMERGED
ARC WELDED (LSAW) LINE PIPE A286-000-11-42-SP-0001 Rev. 0
(ONSHORE) Page 1 of 29
esglkuk cfBaMk ikbiykbZu ifj;kstuk

MEHSANA BATHINDA PIPELINE PROJECT
SPECIFICATION FOR
LONGITUDINAL SEAM SUBMERGED
ARC WELDED (LSAW) LINE PIPE
(ONSHORE)
0 06.09.2012 REVISED & RE-ISSUED AS JOB SPECIFICATION AA NR MSG
C 07.08.2012 REVISED & RE-ISSUED AS JOB SPECIFICATION AA NR MSG
B 25.06.2012 ISSUED AS JOB SPECIFICATION AA NR MSG
A 06.06.2012 ISSUED AS JOB SPECIFICATION AA NR RK VM
Rev. Prepared Checked Approved Approved

Date Purpose
No by by by by

LONGITUDINAL SEAM
SUBMERGED ARC WELDED A286-000-11-42-SP-0001 Rev. 0
(LSAW) LINE PIPE (ONSHORE) Page 2 of 29
Abbreviations:
ASTM American Society for Testing and Materials

API American Petroleum Institute
ID Inside Diameter
ISO International Organization for Standardisation
SAWL Submerged Arc Welded Longitudinal
HAZ Heat Affected Zone
NDT Non Destructive Testing
NPS Nominal Pipe Size
OD Outside Diameter, Specified
WT Wall Thickness, Specified
TDH Through Drill Hole
TPIA Third Party Inspection Agency
QAP Quality Assurance Plan

LONGITUDINAL SEAM
CONTENTS
1 SCOPE....................................................................................................................4
3 NORMATIVE REFERENCES..............................................................................4
6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION.......................4
8 MANUFACTURING.............................................................................................5
9 ACCEPTANCE CRITERIA..................................................................................6
10 INSPECTION.......................................................................................................11
11 MARKING...........................................................................................................14
12 COATING AND THREAD PROTECTOR.........................................................15
13 RETENTION OF RECORDS..............................................................................15
ANNEX – B MANUFACTURING PROCEDURE QUALIFICATION FOR PSL-2 PIPE

(NORMATIVE)
ANNEX – C TREATMENT OF SURFACE IMPERFECTIONS AND DEFECTS

(NORMATIVE)
ANNEX-D REPAIR WELDING PROCEDURE (NORMATIVE)
ANNEX-E NON-DESTRUCTIVE INSPECTION FOR OTHER THAN SOUR SERVICE

OR OFFSHORE SERVICE (NORMATIVE)
ANNEX-Q (NEW) PURCHASER INSPECTION (NORMATIVE)
FIGURE 9.13.3 PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD

FIGURE 10.2.5.5 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN
FIGURE 10.2.5.6 LOCATIONS FOR HARDNESS MEASUREMENT
FIGURE E.1 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM

LONGITUDINAL SEAM
1. SCOPE
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-Fourth Edition, 2007 including
Addendum-3, July 2011 and makes restrictive amendments to API Specification 5L. Unless
modified and / or deleted by this specification, the requirements of API Specification 5L and
Addendum-3 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 (including Addendum 3), 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 product specification
level for line pipe to be supplied as per this specification shall be “PSL 2”.
The Manufacturer shall have a valid license to use API Monogram in accordance with the
requirements of Specification 5L, Forty-Fourth Edition, 2007 on line pipe as Product
Specification Level PSL 2.
1.1 Pipe Size & Grade

(New)
This Specification shall be applied to line pipe of size 18” to 36” & Grade Gr. X65 & X70.
3. NORMATIVE REFERENCES:
The latest edition (edition enforce at the time of issue of enquiry) of following additional
references are included in this specification:
ASTM E112 : Standard Test Methods for Determining Average Grain size
6. PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION
6.1 Pipe grade and steel grade
Line pipe supplied to this specification shall confirm to Product Specification Level PSL 2.
6.2 Delivery condition
6.2.2 Following shall be applicable from Table 3 of API 5L with regards to starting material
Product Specification Level : PSL 2
Delivery Condition : Quenched & Tempered plate

or
Thermo mechanical-rolled strip or plate
Pipe Grade : Gr. X 65 & X 70
6.2.3 For starting material, only plate shall be used above 17.5 mm thickness.
(New)
6.2.4 Testing of raw material (steel) at steel mill shall be witness by TPIA as per steel ITP.
(New)

LONGITUDINAL SEAM
8 MANUFACTURING
8.1 Process of manufacture
Following shall be applicable from Table 2 and Table 3 of API 5L.
Type of pipe : SAWL (Submerged Arc Welded Longitudinal)
Type of pipe end : Plain
Pipe Grade : PSL 2
Starting Material : Quenched and tempered or controlled rolled or combined

rolled and accelerated cooled to impart fine grain structure to
the furnished steel
Pipe forming : Cold Forming
Pipe heat treatment : Nil
Delivery condition : Q or M
8.3 Starting Material
8.3.2 Line pipe furnished to this specification shall be made from steel produced in basic oxygen or
electric arc furnace. Steel shall be made by continuous casting only.
8.3.3 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.
8.4 Tack welds
Tack welds as applicable in SAWL pipe shall be continuous. Manual repair of tack welding
by SMAW shall not be permitted.
8.6 Weld seam
Pipe shall be manufactured with one longitudinal seam. The welding equipment shall have an
automatic weld tracking system (OD/ID) capable of ensuring accurate positioning of welding
head and the welding edges of the strip/ plate, during all stages of welding process including
forming, tack-welding and submerged arc welding.
Continuous data logger shall be used at all welding stations. The use of recycled crushed flux
(previously melted) shall not be permitted.
8.9 Cold sizing and cold expansion
8.9.2 All pipes shall be mechanically cold expanded for full length. The expansion measured on
the circumference shall range between 1.0 to 1.5% of the value before the expansion.
8.9.4 The cold expansion for each pipe shall be measured and recorded.
(New)
8.11 Jointers
Jointers on pipe are not permitted.

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8.13 Traceability Data
8.13.2 The manufacturer shall establish and follow documented procedures for maintaining heat and
test unit identity of all pipes as per requirement of API Spec. 5L and as modified in this
specification.
9 ACCEPTANCE CRITERIA
9.2 Chemical Composition
9.2.2 The chemical composition of each heat of steel on product analysis shall be in accordance
with Table 5 and notes given below. Table 5 of API Spec 5L stands modified as below:
Table – 5: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage
of Weight
Element Product Analysis (percent)

C 0.12 max. (For Grade X65 to X70)
Mn 1.60 max. (For Grade X65 to X70)
Si 0.15 min.
0.45 max.
S 0.015 max.
P 0.02 max.
Al 0.07 max.
Nb Note m (i) (For Grade X65 to X70)
V Note m (i) (For Grade X65 to X70)
Ti Note m (i) (For Grade X65 to X70)
Cr 0.20 max.
Mo 0.10 max. (For Grade X65)
0.20 max. (For Grade X70)
Cu 0.35 max.
Ni 0.20 max.
N 0.012 max.
B 0.0005 max.
Note: m (New)
i. V+Nb+Ti shall not exceed 0.12% (for Grade X65) & 0.15% (for X70)
ii. Cu+Ni shall not exceed 0.50%
iii. Al/N shall be min. 2
Note: n (New)
If alloying elements other than those specified in Table 5 above are added to the steel, the
limits of the additional components shall be agreed with the Purchaser.
Note: o (New)
Minimum for Si is not applicable for Al killed steel.
9.2.4 For PSL2 pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with
the following limits:
CE PCM 0.20 %
Boron content shall be considered in CE PCM formula even if it is less than 0.0005%.
CE IIW 0.40 %
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The CE IIW limits shall not apply if C< 0.12%
9.2.6 Elements Analysed

(New)
For heat analysis and product analysis, all the elements listed in Table 5 of this specification
shall be analysed and reported, even if those are not purposely added but are present as
residuals only.
9.3 Tensile Properties
9.3.2 The finished pipe (after expansion or sizing operations) shall conform to the requirements of
Table 7 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)
X65 to X70 21,700 (149.6)
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 in accordance with cl. 10.2.3.2 during first day production test.
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 (f) of Table-7. However elongation in no case shall be less than 25%.
9.7 Guided Bend Test
One face and one root guided bend test shall be made on sample cut from pipe. The
dimension ‘Agb’ in guided bend test shall not exceed 4.0 times the thickness of the specimen.
The acceptance criteria as per QAP & indicated as below:
a. The specimen shall not fracture completely.
b. The specimen shall not revel any cracks or rupture in the weld metal greater than
3.2mm length regardless of depth.
c. The specimen shall not revel any cracks or rupture in the parent metal, HAZ or
fusion line longer than 3.2mm & deeper than 12.5% of specified wall thickness
except cracks that occur at the edges of the specimen & that are less than 6.4mm
long.
9.8 CVN Impact Test for PSL 2 pipe

(New)
The charpy v notch impact test shall be carried out at (-) 20ºC & 0 ºC. The minimum all heat
average full size absorbed energy value (based on a set of three specimens) for transverse
body specimen, weld and HAZ shall be as per below table.
Base Metal Pipe Weld & HAZ

Test temp.
Avg. Values Individual Values Avg. Values Individual Values
(-) 20ºC 35 J 28 J 27 J 22 J
0ºC 100 J 80 J 40 J 32 J

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In addition the lowest individual absorbed energy value of the three specimens shall not be
less than 80% of the value specified for body, weld and HAZ.
9.8.1.2 Individual test value for any test piece shall not be less than 80% of the value specified.
9.8.2.2 For pipes of all sizes and wall thicknesses, the minimum (set of three test pieces) shear
fracture area for each test shall be at least 85% average & 75% individual, based upon a test
temperature of -20oC(-4°F).
9.8.2.3 First day production test shall be carried out at (-) 25ºC & the energy values shall be same as
(New) (-) 20ºC.
9.9 DWT Test for PSL2 welded pipe
Drop Weight Tear Test in accordance with API Spec 5L and as modified in this specification
shall also be performed for all pipe size, grade and wall thickness.
DWT test shall be carried out for a set of three test pieces at test temperature of -20°C. The
frequency of testing shall be one set of three test pieces per 50 pipes per heat per temp.
Pipe shall be tested at temp.-40°C,-25°C, 0°C & 10°C for shear area avg. shear fracture area
shall be 85% minimum at -20°c (testing at different temperature is only to establish transition
curve) full transition curve shall be established heat out of three with a minimum of one.
9.10 Surface conditions, imperfections and defects
9.10.1.2 Cracks, Sweats and Leaks are not acceptable.
9.10.2 Undercuts
b. Undercuts which can not be classified as mentioned in clause ‘a’ shall be considered
as defect. Disposition shall be as follows:
Undercut defects defined in clause ‘b’ shall be removed by grinding in accordance

with API 5L and as modified in this specification. Complete removal of defects shall
be verified by local visual inspection and by suitable ND inspection method. To be
acceptable, the minus tolerance specified in 9.11.3.1 & 9.11.3.2 shall not apply in the
ground area.
c. Disposition of undercuts exceeding the limits specified in clause ‘b’ shall be in

accordance with (c) or (d) of E10 (annexure-E) of API Spec 5L.
9.10.4 Lamination
Any lamination or inclusion either extending into the face or face of bevel & pipe body with
in manual UT portion or present within 50 mm from pipe ends is considered defect and pipe
containing such defects shall be cut back until such defects are eliminated.
The disposition of lamination and other type of defects on the plate/skelp shall be as per
Annexure-E of API Spec 5L and as modified in this specification.
9.10.5 Geometric Deviations
9.10.5.1 Peaking

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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 E.10 (c) or (d).
9.10.5.2 Dents
Allowable dent size shall be as per API Spec 5L and as modified in this specification.
Disposition of dents shall be carried out in accordance with clause (c) or (d) of E10 (Annex-
E) of API Spec 5L.
a) 3.2 mm for cold formed dents with sharp bottom gouges are not acceptable.
b) 6 mm dents with out any gouges (smooth end) are acceptable.
c) Any dent with gouges is not acceptable.
d) Dents on weld and heat affected zones (HAZ) are not acceptable
9.10.6 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.
9.10.7 Other Surface Imperfections
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 disposed-off in
accordance with clause C.3 and as modified in this specification.
9.11 Dimensions, mass and tolerances
9.11.1.2 This specification shall be applied to line pipe of size 18” to 36” (both size included).
9.11.3 Tolerance for diameter, wall thickness, length and straightness
9.11.3.1 Diameter
Tolerance for diameter and out-of-roundness shall be as under and Table 10 of API Spec 5L
stands modified accordingly.
Diameter Tolerance
Pipe Body
The outside diameter of pipe body, as determined by taping the circumference, shall not
deviate by more than the values given below.
Size Tolerance
18 and 36 3 mm
Pipe Ends
Diameter tolerances for the pipe ends indicated in API Spec 5L, Table 10 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/ISO 3183. Inside diameter
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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 Tolerance
Pipe Body
Out of roundness tolerance on pipe body, indicated in API Spec 5L, Table 10 shall be
applicable:
Pipe End
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 : 4.0 mm
Out of roundness tolerance indicated in API Spec 5L, Table 10 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).
9.11.3.2 Wall Thickness
The wall thickness tolerance shall comply with the requirements of this specification.
The tolerances on specified wall thickness shall be (+) 10% and (-) 0%. API Spec 5L, Table
11 stands cancelled.
Wall thickness shall be measured and recorded for each pipe.
9.11.3.3 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 pipes from which samples are
taken for testing. The minimum average length of the entire ordered quantity in any case shall
be 12.0m. API Spec 5L, clause no. 9.11.3.3 & Table 12 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.
9.11.3.4 Straightness
The total deviation from a straight line over the entire pipe length for all pipe sizes shall not
exceed 10 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).
The local deviation from a straight line at each pipe end (1000mm portion) specified in
clause ‘b’ shall not be allowed.

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9.12 Finish of Pipe Ends
9.12.5 Plain Ends

Pipes shall be furnished with 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 9.11.3.2 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.
9.12.6 Both pipe ends of each pipe shall be provided with metallic or high impact plastic bevel
(New) 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.
9.13.1 Radial Offset of Strip / 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).
9.13.2 Height of the flash or weld bead / reinforcement
The maximum height of outside and inside weld bead shall be min. 0.5 mm & max. 3.2 mm
for all specified wall thickness. Table-16 of API 5L shall stands modified. 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).
9.13.3 Misalignment of the weld beads of SAW Pipes
A misalignment of weld seam exceeding 2.0 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 9.13.3 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 &
macro graphic examination specimen as stated at para 10.2.5 and as modified in this
specification.
10 INSPECTION
10.2.1 Inspection Frequency
10.2.1.2 The frequency of Inspection and testing shall be as per QAP document no. A286-000-11-42-
QAP-0001.
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.

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Product Analysis:
Two samples per test unit shall be analysed. Test unit shall be 50 pipes per heat per size.
Pipes selected shall be such that one at the beginning of the heat and one at the end of the
heat are also represented.
Tensile Test Frequency (For Pipe body & Weld Seam):
Tensile tests shall be made at the frequency of two (02) set per test unit per heat per size as
per QAP. Set shall consist of two samples one for weld one for body:
Test unit shall consist of 50 pipes that are made to the same size and the same specified wall
thickness by the same process, from the same heat and under the same manufacturing
conditions.
Charpy Impact Test:
The minimum test frequency shall be one set per 100 pipes per heat per temp. per
combination of pipe size and specified wall thickness. The set shall consist of three
specimens each from Body, FL, FL+2mm FL+4mm in transverse direction.
DWT Test:
The minimum test frequency shall be one set per 50 pipes per heat per temp. per combination
of pipe size and specified wall thickness.
Metallographic Examination
A test specimen for metallographic & hardness examination shall be taken transverse to the
longitudinal weld, from one finished pipe from each test unit of 50 pipes per heat per welding
line 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 minimum Test frequency for Hardness test shall be one sample per 50 pipes heat per
welding line during regular production.
Guided Bend test
The minimum test frequency shall be one set per 50 pipes per heat. The set shall consist of
one face guided bend & one root guided bend test piece cut from the pipe.
Dimensional measurements:
Each pipe shall be measured for following:

Visual inspection, pipe diameter & out of roundness, wall thickness, pipe weight, length etc.
as per API 5L and as modified in this specification. All dimensions and tolerances shall be
measured and recorded at least three times per operating shift (12 hrs max.).
API 5L Table 18 of Addendum-3 shall be considered applicable for the tests which are
not covered in this specification.
10.2.2 Samples and test pieces for product analysis
Sample 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.

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10.2.3.2 Test Piece for the Tensile Test
The transverse tensile tests shall be carried out on flattened rectangular specimen only.
For weld tensile test 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- B of API 5L and as modified in this specification, to determine the
ultimate tensile strength 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 of any change in batch of wire-flux combination.
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.
10.2.4 Test methods
10.2.4.3 CVN Impact Test
The Charpy test shall be carried out in accordance with ASTM A370 and the required striker
radius shall be 8mm.
10.2.5 Macrographic and Metallographic tests
10.2.5.5 The specimen extraction shall be as per Fig. 10.2.5.5 of this specification. The specimen shall
(New) 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 as deemed necessary by
Purchaser's Representative.
10.2.5.6 Vickers hardness tests shall be carried out on each specimen taken for Metallographic
(New) Examination in accordance with ASTM E-92, at locations indicated in Fig. 10.2.5.6 of this
specification. 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.
The maximum difference in hardness between base material & any reading taken on weld or
HAZ shall be less than 80 HV10. Modalities of retest shall be in accordance with API Spec.
5L.
10.2.5.7 In Metallographic test, no untempered martensite remains & uniformly distributed ferritic
(New) structure shall be established and fusion line shall be clearly visible. The grain size shall be 7
or finer as per ASME E 112.
10.2.6 Hydrostatic Test
10.2.6.1 Hydrotest shall be carried out after cold expansion. Test pressure shall be held for a minimum
period of 15 seconds for all sizes and grades of pipes. Each pipe shall be hydrostatically
tested during both regular & first day production.

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10.2.6.2 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 at beginning of every shift
shall be calibrated by means of a "Dead Weight" tester only.
The test pressure for all sizes and grades of pipe shall be such that hoop stress (fibre stress)
generated is equivalent to 100% of SMYS, computed based on the formula mentioned in API
Spec 5L para 10.2.6.5.
10.2.6.8 Calibration of pressure gauge shall be done at start of an each shift (12 hrs max.) &
(New) calibration of hydro tester with 1.6 mm TDH shall be carried out at beginning of each shift.
10.2.7 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.
10.2.8 Dimensional Testing
10.2.8.5 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.
10.2.11 Reprocessing
This para stands Cancelled.
10.2.12 Retesting
10.2.12.1 Recheck Analysis
Modalities of recheck analysis shall be as per API Spec. 5L and (Addendum 3) as applicable
to the test unit being tested (refer para 10.2.1.2 of this specification). However, during
individual testing, each pipe shall be fully analysed to meet the requirements of Table 5 of
this specification.
11 MARKING
In addition of the requirement specified in API 5L for pipe marking, following shall also be
applicable.
- Marking shall also include Purchase Order number, item number, pipe number, heat
number and weight.
- 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.
- Actual pipe weight in kg shall also be marked.

- 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.
- Actual length shall be marked in metres.

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- 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.
- Bar code shall be provided on each pipe two nos., one on external surface & other on
internal surface at opposite end. Bar coding procedure shall be submitted for
owner/TPIA approval. Radio frequency identification (RF-ID) shall be provided for
all bare pipes.
12 COATING AND THREAD PROTECTOR
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.
13 RETENTION OF RECORDS
In addition to the records indicated in clause 13 of API Spec 5L, 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.
13.1 Production Report
(New) The Manufacturer shall provide eight copies including soft files in scanned & excel format 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:
- Test certificates for all test (as applicable) mentioned in clause 10.2.4 of API 5L.
- Records of qualification of welders and procedures for repair welding.
- Certified reports of dimensional, workmanship and defects inspection.
- Data on test failures, rejected heats/test units, 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 API Spec 5L and other
test reports/results required as per this specification.

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Annex - B
(Normative)
B.3 Characteristics of the Manufacturing Procedure Specification
Clause no. a. viii) of API 5L Addendum 3 stands deleted.
B.5 Manufacturing Procedure Qualification (MPS) for PSL 2 Pipe
The requirements specified in API 5L (Addendum 3) shall be followed with Manufacturing

procedure qualification test (B.5) as modified herein with first day production test:
Minimum two pipes each of completely finished pipes of first day's production from three different
heats 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 test unit 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.
First day production shall be carried out as per approved welding procedure specification. Mill
parameters established during first day shall be followed in regular production.
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 & QAP 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.
Manufacturer has to retain films up to 5 years.

LONGITUDINAL SEAM
d. Product Analysis:
Two (02) samples per pipe shall be tested for chemical analysis as per this specification.
e. 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. Guided Bend Test: Four (4) weld guided bend test specimen transverse to the
longitudinal weld shall be removed. Out of the four specimens, two specimens shall
be used for the face bend test and two for the root bend test.
ii. Tensile test: 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. Metallographic Examination (Macro & Micro): Six (6) weld cross-section specimen
per pipe, three (3) from each end of the pipe joint, shall be taken for metallographic
examination.
iv. Hardness Test: Two (2) samples per pipe shall be tested for hardness at room
temperature after etching. Hardness test shall be conducted on selected pipes as per
requirement of para 10.2.5 of this specification.
v. Fracture toughness test: Specimen shall be extracted as follows:

One set per pipe per temp. of three specimens each from FL, FL+2mm, FL+4mm &
body in transverse orientation shall be tested. The test shall be carried out at -25°C.
Energy values at -25°C shall be same as -20°C as per Clause no. 9.8 of this
specification.
The base metal specimen shall be tested at -40°C,-25°C, 0°C & 10°C for shear area
and absorbed energy to produce full transition curve. Shear fracture area for each
test shall be at least 85% average & 75% individual, based upon a test temperature
of -20oC.
vi. Drop Weight Tear Test: One set of three test pieces per heat per temp DWTT
specimens shall be removed from base metal in a transverse direction. DWT test
shall be carried out at test temperature of -20°C.
Pipe shall be tested at temp.-40°C,-25°C, 0°C & 10°C for shear area avg. shear
fracture area shall be 85% minimum at -20°c (testing at different temperature is only
to establish transition curve) full transition curve shall be established heat out of
three with a minimum of one.
f. Burst Test:
One pipe for each size and grade on lowest thickness & higher thickness per steel supplier
shall be subjected to burst test. Burst test pressure shall be such that hoop stress generated is
equivalent to 125% of SMYS (minimum). Burst test pressure & location shall be recorded. If

LONGITUDINAL SEAM
burst pipe fails below 125% of SMYS then manufacture shall investigate the root cause &
submit the report to the client before retesting & restarting of the regular production.
g. Cyclic Hydrotest:
Cyclic hydrotest shall be carried out for 1 hour at 50% of highest test pressure (HTP), 1 hour
at 75% of HTP & 24 hours at 100% of HTP. Automatic continuous recording on the graph
(time/press.) shall be carried out. Pressure shall drop upto static head +1 bar per cycle. Test
shall be carried out one test per size per grade per lowest thickness.
h. Weldability Test:
(New)
Manufacturer shall carry out a weldability test to establish that quality girth welding meeting
various requirements mentioned in this specification can be achieved The Test shall be
performed on one pipe of each size on lowest thickness. Welding shall be carried out as per
approved welding procedure specification/ PQR of EPC contractor be joining two full length
pipe with internal clamps. All test (Tensile, test, Guided Bend test, Hardness test, Charpy
test, DWTT, NDT-100% Radiography & UT etc.) shall be performed as per this
specification. Micro examination shall be carried out as per API 1104. Welding procedure
shall comply the requirements of API 1104. In case of failure of any test results to comply the
specification requirements, manufacturer shall revise the welding procedure adopted and
carry out the tests again to comply the specification requirements. Manufacturer shall submit
the test results to Purchaser to comply specification requirements prior to shipment/ dispatch
of pipes.
i. In addition, all the tests and inspections require to be conducted as per this specification,
QAP & API 5L (including Addendum-3) shall be conducted on all the pipes selected for
testing during first day production test

LONGITUDINAL SEAM
Annex - C
(Normative)
Treatment of surface imperfections and defects
C.1 Treatment of surface imperfections
Surface imperfection not classified as defect as per clause 9.10.7 (and as modified in this
specification) shall be cosmetically dressed-out by grinding.
C.2 Treatment of dressable surface defects
C.2.3 Complete removal of defects shall be verified by local visual inspection and by suitable non-
destructive inspection. To be acceptable, the wall thickness in the ground area shall be in
accordance with 9.11.3.2 and as modified in this specification.
C.4 Repair of defects by welding
Repair of pipe body by welding is not permitted.
C.4.9 The defective part of the weld shall be clearly marked on the pipe so that the defect can be
(New) easily located and repaired. Approval for each repair shall be taken from TPIA before
proceeding further.
C.4.10 Following requirements shall also be complied with for repair welding:
(New)
a. Defect shall be completely removed by grinding & the same confirmed by Dye Penetrate
test.
b. No repair of weld seam is permissible after cold expansion.
c. No repair of weld seam is permissible at pipe ends up to a length of 300 mm or one
diameter of pipe whichever is largest.
d. Maximum two repairs per pipe length are allowed.
e. Total length of repaired zone on each weld is limited to 5% of total weld length.
f. Distance between two repairs shall not be less than one diameter of pipe.
g. The weld repairs shall have minimum length of 100mm, even if the defect is of lesser
extent.
h. An interruption of SAW is not considered as a repair unless unacceptable defects are
found.
i. Repair welding on parent metal is not permitted. Only low hydrogen electrode shall be
used.
j. Repair welding shall be executed only after specific approval by TPIA for each repair
and to be radiographed & Manual UT.
k. No repair of a repaired weld is permitted.
l. Repaired welds shall be inspected both by X-ray and UT.
C.4.11 The Manufacturer shall also maintain a record of repairs carried out. The records shall include
(New) repair number, pipe identification number, welding procedure applicable and NDT details.

LONGITUDINAL SEAM
Annex - D
(Normative)
Repair Welding Procedure
D.1 General
D.1.6 No repair of weld seam is permissible at pipe ends up to a length of 300 mm or one diameter
of pipe whichever is largest.
(New)
D.2.3 Mechanical Testing
D.2.3.2 Transverse Tensile Test
D.2.3.2.1The transverse tensile test piece shall be prepared as per API 5L. The specimen edge shall be
machined and no oxygen cut is allowed.
D.2.3.3 Transverse Guided bend test
The radius of curvature of the Jig used for guided bend tests shall be r a = 2.25t, where t is
specified wall thickness of pipe.
D.2.3.4 Charpy (CVN) impact test
The CVN impact test shall be carried out in accordance with the requirements of para 9.8 and
para 10.2.4.3 of this specification.
D.2.3.5 Hardness test as specified in para 10.2.5.5 of this specification shall be included in the
(New) procedure qualification. The location of the hardness measurements is to be indicated taking
into account the new HAZ of the repaired area.

LONGITUDINAL SEAM
Annex - E
(Normative)
Non-destructive inspection for other than sour service or offshore service
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 the annexure-Q (New)
of the specification. 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.
E.1 Qualification of Personnel
All personnel performing NDT activities shall be qualified in the technique applied, in
accordance with latest edition of ISO 11484 or ASNT SNT-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).
(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)
Note: Levels 1, 2 and 3 is ISO 11484 corresponds to levels I, II and II in ASNT SNT-TC-1A
E.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.
HR Plate/Coil Inspection
The entire width & length of each HR coil/plate shall be 100% ultrasonically inspected by
placing array probes on the HR coil/plate surface.
The height of indication having amplitude beyond the reference accepted signal height (100%
at 80% FSH) is considered as defective indication. Locations showing indications above the
acceptance limits may be re-examined by manual ultrasonic method. Acceptance criteria,
Calibration standard & Frequency shall be as per QAP for both automatic & Manual UT
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

LONGITUDINAL SEAM
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.
Magnetic Particle Inspection
Each pipe weld seam OD, weld seam ID & both the bevel end shall be magnetic particle
inspected as per QAP. Frequency OD weld seam shall be five pipes per shift. In case no
indications are observed in the first three shifts the frequency will be reduced to one pipe per
shift.
AUT of Body & Weld seam
AUT of weld seam & body shall be as per QAP. Calibration frequency & standard shall be as
per QAP. Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table E.1)
using automatic ultrasonic equipment in accordance with API Spec 5L para E.5 and as
modified in this specification. Pipe end welds shall be inspected in accordance with Para
E.3.2.
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 10.2.5.3 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.
E.3.2 Pipe End Inspection – Welded Pipe
The weld at pipe ends not covered by automatic ultrasonic equipment shall be inspected by
manual ultrasonic equipment with same sensitivity and capability as automatic equipment.
In addition to the MUT confirmed indications, 0.2% of total ordered length shall be
radiographed at least at the middle of the pipe as per QAP.
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.
E.4 Radiographic Inspection of Weld Seams
E.4.2 Radiographic Inspection Equipment
E.4.2.1 The homogeneity of weld seams examined by radiographic methods shall be determined by
means of X-rays directed through the weld material in order to create a suitable image on
radiographic film.
E.4.2.2 The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table 2 of
ASTM E 94 or ISO 11699-1:1998 class T2 or class T3 or ASTM E1815-06, class I or class
II, and shall be used with lead screens.
E.4.2.3 The density of the radiograph shall be not less than 2.0 and shall be chosen such that:
a) The density through the thickest portion of the weld seam is not less than 1.8.
b) The maximum contrast for the type of film used is achieved.

LONGITUDINAL SEAM
E.4.6 Defects found by Radiographic 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.
E.5 Ultrasonic and Electromagnetic Inspection
E.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 and probe de-coupling. 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.
E.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 as the pipe being inspected.
The reference standard for weld UT shall contain machined notches/holes as per Figure E.1
of this specification and as given below:
- Two longitudinal inside notches of type N 5 at both edges of weld seam.

- Two longitudinal outside notches of type N5 at both edges of weld seam.
- Two longitudinal notches of type N5 at the centre of the weld seam, one outside and
one inside.
- Two transverse notches of type N5 across the weld seam, one outside and one
inside.
- A drilled hole in the centre of the weld seam, of diameter equal to 1.6 mm
The reference standard for plate/skelp UT shall contain continuous machined notch of 8 mm
width x ½ 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 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) and subsequently
every 4 hours.
b. Every time there is change in probes or working condition of the UT machine.
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 TPIA, all the pipes or plate/skelp already inspected after
the previous verification shall be inspected again at Manufacturer's cost.

LONGITUDINAL SEAM
E.5.5.5 Acceptance limits

(New)
E5.5.5.1 Acceptance limits for plate/coil, pipe body & all weld seams shall be as per QAP
E.7 Residual Magnetism
E.7.6 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.
E.8 Laminar imperfections in the pipe body
E.8.2 Ultrasonic inspection shall be used to verify that the strip/plate or the pipe body is free of
laminar imperfections greater than those permitted by ISO 12094:1994, acceptance level B2.
E.10 Disposition of pipes 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
(c) or (d).

LONGITUDINAL SEAM
Annexure- Q (New)
PURCHASER INSPECTION (NORMATIVE)
Q.1 Inspection Notice
Where the inspector representing the purchaser desires to inspect pipe or witness tests,
reasonable notice shall be given of the time at which the run is to be made.
Q.2 Plant Access
The inspector representing the purchaser shall have unrestricted access, at all times while
work of the contract of the purchaser is being performed, to all parts of the manufacturer’s
works that will concern the manufacture of the pipe ordered. The manufacturer shall afford
the inspector all reasonable facilities to satisfy the inspector that the pipe is being
manufactured in accordance with this specification. All inspections should be made at the
place of manufacture prior to shipment, unless otherwise specified on the purchase order, and
shall be so conducted as not too interfere unnecessarily with the operation of the works.
Q.3 Compliance
The manufacturer is responsible for complying with all of the provisions of this specification.
The purchaser may make any investigation necessary to be satisfied of compliance by the
manufacturer and any reject any material that does not comply with this specification.
Q.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.

LONGITUDINAL SEAM
FIGURE: 9.13.3
X-RAY FILM
PROCEDURE FOR MEASUREMENT OF

OUT OF LINE WELD BEAD

LONGITUDINAL SEAM
FIGURE: 10.2.5.5
METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

LONGITUDINAL SEAM
- LOCATIONS WHERE HARDNESS MEASUREMENT TO BE CARRIED OUT
FIGURE: 10.2.5.6
LOCATIONS FOR HARDNESS MEASUREMENT

LONGITUDINAL SEAM
FIGURE: E.1
REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM
1,2 - Longitudinal inside notch at weld seam edge

3,4 - Longitudinal outside notch at weld seam edge
5 - Transverse inside notch at weld seam edge
6 - Transverse outside notch at weld seam edge
7 - Longitudinal inside notch at weld seam centre
8 - Longitudinal outside notch at weld seam centre
9 - 1.6 mm dia. through thickness hole.

SPECIFICATION FOR HELICAL DOCUMENT No.
(SPIRAL) SEAM SUBMERGED ARC
WELDED (HSAW) LINE PIPE A286-000-11-42-SP-0004 Rev. 0

SPECIFICATION FOR HELICAL (SPIRAL)

SEAM SUBMERGED ARC
WELDED (HSAW) LINE PIPE
(ONSHORE)
0 06.09.12 REVISED & RE- ISSUED AS JOB SPECIFICATION AA NR MSG
C 07.08.12 REVISED & RE- ISSUED AS JOB SPECIFICATION AA NR MSG
B 26.06.12 ISSUED AS JOB SPECIFICATION AA NR MSG
A 05.06.12 ISSUED AS JOB SPECIFICATION MPS NR MSG

Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

(SPIRAL) SEAM SUBMERGED A286-000-11-42-SP-0004 Rev. 0
ARC WELDED (HSAW) LINE
PIPE (ONSHORE) Page 2 of 30
Abbreviations:

ID Inside Diameter
ISO International Organization for Standardisation
SAWH Submerged Arc Welded helical

CONTENTS
1 SCOPE...........................................................................................................................4
3 NORMATIVE REFERENCES.....................................................................................4
6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION.........................4
8 MANUFACTURING....................................................................................................5
9 ACCEPTANCE CRITERIA.........................................................................................6
10 INSPECTION..............................................................................................................12
11 MARKING..................................................................................................................15
12 COATING AND THREAD PROTECTOR................................................................16
13 RETENTION OF RECORDS.....................................................................................16

(NORMATIVE)
ANNEX – C TREATMENT OF SURFACE IMPERFECTIONS AND DEFECTS (NORMATIVE)
ANNEX-D REPAIR WELDING PROCEDURE (NORMATIVE)
ANNEX-E NON-DESTRUCTIVE INSPECTION FOR OTHER THAN SOUR SERVICE OR

OFFSHORE SERVICE (NORMATIVE)
FIGURE 9.13.3 PROCEDURE FOR MEASUREMENT OF OUT OF LINE WELD BEAD

FIGURE 10.2.5.5 METALLOGRAPHIC SPECIMEN EXTRACTION PLAN
FIGURE E.1 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD SEAM

1. SCOPE
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-Fourth Edition, 2007 including Addendum-3, July
2011 and makes restrictive amendments to API Specification 5L. Unless modified and / or deleted
by this specification, the requirements of API Specification 5L and Addendum-3 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 (including Addendum-3), have also been numbered and marked as "(New)".
The coverage by this specification is limited to line pipe to be used for onshore pipelines
transporting non-sour hydrocarbons in liquid or gaseous phase. The product specification level for
line pipe to be supplied as per this specification shall be “PSL2”.
requirements of Specification 5L, Forty-Fourth Edition, 2007 on line pipe as Product Specification
Level PSL 2.

(New)
This Specification shall be applied to line pipe of size 18” to 36” & Grade X65 & X70.
3. NORMATIVE REFERENCES:
The latest edition (edition enforce at the time of issue of enquiry) of following additional
ASTM E112 : Standard Test Methods for Determining Average Grain size
Line pipe supplied to this specification shall conform to Product Specification Level PSL 2.
6.2.2 Following shall be applicable from Table 3 of API 5L with regards to starting material.
Delivery Condition : Thermo mechanical-rolled strip
Pipe Grade : Gr. X65 & X70
6.2.3 Testing of raw material (steel) at steel mill shall be witness by TPIA as per steel ITP
(New)

8 MANUFACTURING
Type of pipe : SAWH (Submerged Arc Welded Helical)
Pipe Grade : PSL 2
Starting Material : Thermomechanical-rolled Strip
Pipe heat treatment : Nil
Delivery condition : M
8.3.2. Line pipe furnished to this specification shall be made from steel produced in basic oxygen or
8.3.3 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.
8.3.4 The width of the coil used for the manufacture of pipe shall not be less than 0.8 times or more than
3.0 times the specified OD of the pipe.
8.3.6 All pipes shall be manufactured by offline (two steps) mill.

(New)
8.3.7 Central Slitting of coils are not permitted.
(New)
8.4 Tack welds
Tack welds as applicable in SAWH pipe shall be continuous. Manual repair of tack welding by
SMAW shall not be permitted.
8.6 Weld seam
Pipe shall be manufactured with one helical seam. The welding equipment shall have an automatic
weld tracking system (OD/ID) capable of ensuring accurate positioning of welding head and the
welding edges of the skelp, during all stages of welding process including forming, tack-welding
and submerged arc welding.
Continuous data logger shall be used at all welding stations. The use of recycled crushed flux
(previously melted) shall not be permitted.
8.9.2 Pipe furnished to this specification shall be non-expanded.

8.10 Strip end welds
8.10.2 Junctions of skelp end welds and helical seam welds in finished pipe are not permitted.
8.11 Jointers
8.12 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.
8.13 Traceability data
8.13.2 The manufacturer shall establish and follow procedures for maintaining heat and test unit identity
of all pipes as per requirement of API Spec. 5L and as modified in this specification.
9.2.2 The chemical composition of each heat of steel on product analysis shall be in accordance with
Table 5 and notes given below. Table 5 of API Spec 5L stands modified as below:
Table – 5: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage of
Weight

C 0.12 max. (For Grade X65 & X70)
Mn 1.60 max. (For Grade X65 & X70)
Si 0.15 min.
0.45 max.
S 0.015 max.
P 0.02 max.
Al 0.07 max.
Cr 0.20 max.
Mo 0.10 max. (For Grade X65)
0.20 max. (For Grade X70)
Cu 0.35 max.
Ni 0.20 max.
N 0.012 max.
B 0.0005 max.
Note: m (New)
i. V+Nb+Ti shall not exceed 0.12% (for Grade X65) and 0.15% (for Grade X70)
Note: n (New)
If alloying elements other than those specified in Table 5 above are added to the steel, the limits of
the additional components shall be agreed with the Purchaser.
Note: o (New)
Minimum for Si is not applicable for Al killed steel.
9.2.4 For PSL2 pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the
following limits:
CE PCM 0.20 %
Boron content shall be considered in CE PCM formula even if it is less than 0.0005%.
9.2.5 For PSL2 pipes of all grades, size and wall thickness, Carbon Equivalent shall comply with the
following limits:
CE IIW 0.40 %
The CEIIW limits shall not apply if C< 0.12%

(New)
For heat analysis and product analysis, all the elements listed in Table 5 of this specification shall
be analysed and reported, even if those are not purposely added but are present as residuals only.
9.3.2 The finished pipe shall conform to the requirements of Table 7 of API Spec 5L and as modified
herein.
X65 to X70 21,700 (149.6)
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
in accordance with cl. 10.2.3.2 during first day production test.
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 (f) of Table-7. However elongation in no case shall be less than 25%.
9.7 Guided Bend Test
One face and one root guided bend test shall be made on sample cut from pipe. The frequency of
testing shall be same as for tensile test. The dimension ‘Agb’ in guided bend test shall not exceed
4.0 times the thickness of the specimen. The acceptance criteria as per QAP & indicated below:
a. The specimen shall not fracture completely.
b. The specimen shall not revel any cracks or rupture in the weld metal greater than 3.2mm
length regardless of depth.
c. The specimen shall not revel any cracks or rupture in the parent metal, HAZ or fusion line
longer than 3.2mm & deeper than 12.5% of specified wall thickness except cracks that
occur at the edges of the specimen & that are less than 6.4mm long.

The Charpy V notch impact test shall be carried out at (-) 20ºC & 0 ºC. The minimum all heat
average full size absorbed energy value (based on a set of three specimens) for transverse body
specimen, weld and HAZ shall be as per below table.
Base Metal Weld & HAZ

Test temp.
(-) 20ºC 35 J 28 J 27 J 22 J
0ºC 100 J 80 J 40 J 32 J
In addition the lowest individual absorbed energy value of the three specimens shall not be less
than 80% of the value specified for body, weld and HAZ.
9.8.2.2 For pipes of all sizes and wall thicknesses, the minimum (set of three test pieces) shear fracture
area for each test shall be at least 85% average & 75% individual, based upon a test temperature of
-20oC(-4°F).
(New) (-) 20ºC.
9.9 DWT Test for PSL2 welded pipe
Drop Weight Tear Test in accordance with API Spec 5L and as modified in this specification shall
also be performed for all pipe size, grade and wall thickness.
DWT test shall be carried out for a set of three test pieces at test temperature of -20°C. The
frequency of testing shall be one set of three test pieces per 50 pipes per heat per temp.
Pipe shall be tested at temp.-40°C,-25°C, 0°C & 10°C for shear area average shear fracture area
shall be 85% minimum at -20°C (testing at different temperature is only to establish transition
curve) full transition curve shall be established heat out of three with a minimum of one.
9.10.1.2 Cracks, Sweats and Leaks are not permitted.
9.10.2 Undercuts
b. Undercuts which can not be classified as mentioned in clause ‘a’ shall be considered as
defect. Disposition shall be as follows:
Undercut defects defined in clause ‘b’ shall be removed by grinding in accordance with API
5L and as modified in this specification. Complete removal of defects shall be verified by
local visual inspection and by suitable ND inspection method. To be acceptable, the minus
tolerance specified in 9.11.3.1 & 9.11.3.2 shall not apply in the ground area.
c. Disposition of undercuts exceeding the limits specified in clause ‘b’ shall be in accordance
with (c) or (d) of E10 (annexure-E) of API Spec 5L.

9.10.4 Lamination
Any lamination or inclusion either extending into the face or face of bevel & pipe body with in
manual UT portion or present within 50 mm from pipe ends is considered defect and pipe
The disposition of lamination and other type of defects on the skelp shall be as per Annexure-E of
API Spec 5L and as modified in this specification.
9.10.5.1 Peaking
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 E.10 (c) or (d).
9.10.5.2 Dents
Allowable dent size shall be as per API Spec 5L and as modified in this specification. Disposition
of dents shall be carried out in accordance with clause (c) or (d) of E10 (Annex-E) of API Spec 5L.
a) 3.2 mm for cold formed dents with sharp bottom gouges are not acceptable.
9.10.6 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.
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 disposed-off in accordance with
clause C.3. and as modified in this specification.
9.11.1.2 This specification shall be applied to line pipe of size 18” to 36” (both size included).
9.11.3.1 Diameter
Tolerance for diameter and out-of-roundness shall be as under and Table 10 of API Spec 5L stands
modified accordingly.
Diameter Tolerance
Pipe Body
The outside diameter of pipe body, as determined by taping the circumference, shall not deviate by
more than the values given below.
Size Tolerance
18 and 36 3 mm
Pipe Ends
Diameter tolerances for the pipe ends indicated in API Spec 5L, Table 10 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/ISO 3183. Inside diameter is defined as
ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside diameter and
specified wall thickness respectively.
Pipe Body
Out of roundness tolerance on pipe body, indicated in API Spec 5L, Table 10 shall be applicable.
Pipe End
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 : 4.0 mm
Out of roundness tolerance on pipe end indicated in API Spec 5L, Table 10 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.
tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs. maximum).
The tolerances on specified wall thickness shall be (+) 10% and (-) 0%. API Spec 5L, Table 11
stands cancelled.
9.11.3.3 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 pipes from which samples are taken for
testing. The minimum average length of the entire ordered quantity in any case shall be 12.0m.
API Spec 5L, clause no. 9.11.3.3 & Table 12 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.

The total deviation from a straight line over the entire pipe length for all pipe sizes shall not exceed
10 mm. Each pipe shall be checked for conformance to this requirement. Straightness shall be
The local deviation from a straight line at each pipe end (1000mm portion) specified in clause ‘b’
shall not be allowed.
9.12.5 Plain Ends

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 9.11.3.2 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
(New) 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.
9.13.1 Radial Offset of Strip 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).
9.13.2 Height of the flesh or weld bead / reinforcement
The maximum height of outside and inside weld bead shall be min. 0.5 mm & max. 3.2 mm for all
specified wall thickness. Table-16 of API 5L shall stand modified. 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).
9.13.3 Misalignment of the weld beads of SAW Pipes
A misalignment of weld seam exceeding 2.0 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 9.13.3 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 & macro
graphic examination specimen as stated at para 10.2.5 and as modified in this specification.
9.16 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 before & after hydrostatic test.

9.16.1 Testing Frequency

(New)
One test per heat 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.
9.16.2 Test Specimen

(New)
The test 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.
9.16.3 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)
9.16.4 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 108 kPa, (29 x 106 psi)
R - Pipe Radius, mm (0.5 * Specified outside diameter), mm (in)
F - 0.1154 in SI units, (0.425 in conventional units)
9.16.5 Acceptance Criteria

(New)
The computed residual stress shall not exceed 10% of the Specified Minimum Yield Stress
(SMYS) of the pipe.
10 INSPECTION
10.2.1.2 The frequency of Inspection and testing shall be as per QAP document no. A286-000-11-42-QAP-
0004.
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.
Product Analysis:
Two samples per test unit shall be analysed. Test unit shall be 50 pipes per heat per size. Pipes
selected shall be such that one at the beginning of the heat and one at the end of the heat are also
represented.

Tensile Test Frequency (For Pipe body & Weld Seam):
Tensile tests shall be made at the frequency of two (02) set per test unit per heat per size as per
QAP. Set shall consist of two samples one for weld one for body:
thickness by the same process, from the same heat and under the same manufacturing conditions.
Charpy Impact Test:
The minimum test frequency shall be one set per 100 pipes per heat per temp. per combination of
pipe size and specified wall thickness. The set shall consist of three specimens each from Body,
FL, FL+2mm FL+4mm in transverse direction.
DWT Test:
The minimum test frequency shall be one set per 50 pipes per heat per temp. per combination of
pipe size and specified wall thickness.
Metallographic Examination
longitudinal weld, from one finished pipe from each test unit of 50 pipes per heat per welding line
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 minimum Test frequency for Hardness test shall be one sample per 50 pipes heat per welding
line during regular production.
Guided Bend test
The minimum test frequency shall be one set per 50 pipes per heat. The set shall consist of one
face guided bend & one root guided bend test piece cut from the pipe.

Visual inspection, pipe diameter & out of roundness, wall thickness, pipe weight, length etc. as per
API 5L and as modified in this specification. All dimensions and tolerances shall be measured and
recorded at least three times per operating shift (12 hrs max.)
API 5L Table 18 of Addendum-3 shall be considered applicable for the tests which are not
covered in this specification.
10.2.3 Samples and test pieces for mechanical tests
Sample 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.

For weld tensile test 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- B of API 5L and as modified in this specification, to determine the ultimate
tensile strength 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 of any change in batch of wire-flux combination.
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 skelp with regard to yield,
tensile and elongation.
10.2.4 Test methods
radius shall be 8 mm.
10.2.5 Macrographic and Metallographic Tests
10.2.5.5 The specimen extraction shall be as per Fig. 10.2.5.5 of this specification. The specimen shall
(New) 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 as deemed necessary by Purchaser's Representative.
10.2.5.6 Vickers hardness tests shall be carried out on each specimen taken for metallographic
(New) Examination in accordance with ASTM E-92, at locations indicated in Fig. 10.2.5.6 of this
possible. The resulting Vickers hardness value at any point shall not exceed 248 HV10. The
maximum difference in hardness between base material & any reading taken on weld or HAZ shall
be less than 80 HV10. Modalities of retest shall be in accordance with API Spec. 5L.
10.2.5.7 In Metallographic, no untendered martensite remains & uniformly distributed ferritic structure
(New) shall be established & fusion line shall be clearly visible. The grain size shall be ASTM E 7 or finer
as per ASTM E112.
10.2.6.1 Test pressure shall be held for a minimum period of 15 seconds for all sizes and grades of pipes.
Each pipe shall be hydrostatically tested during both regular & first day production.
maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means of a
"Dead Weight" tester only.

equivalent to 100% of SMYS, computed based on the formula mentioned in API Spec 5L para
10.2.6.5.
10.2.6.8 Calibration of pressure gauge shall be done at start of a each shift (12 hours max.) & calibration of
(New) hydrotester with 1.6 mm TDH shall be carried out at beginning of each shift.
10.2.7 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.
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.
This para stands Cancelled.
10.2.12 Retesting
10.2.12.1Recheck Analysis
Modalities of recheck analysis shall be as per API Spec. 5L (including Addendum-3) to the test
unit being tested (refer para 10.2.1.2 of this specification). However, during individual testing,
each pipe shall be fully analysed to meet the requirements of Table 5 of this specification.
11 MARKING
applicable.
number and weight.
- 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.
- 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.
- 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.
internal surface at opposite end. Bar coding procedure shall be submitted for owner/TPIA
approval. Radio frequency identification (RF-ID) shall be provided for all bare pipes.
12 COATING AND THREAD PROTECTOR
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.
In addition to the records indicated in clause 13 of API Spec 5L, 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.

production report in English language indicating at least the following for each pipe. International
System of units (SI) shall be adopted.
- Pipe number
- 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:
- Records of qualification of welders and procedures for repair welding.
- Data on test failures, rejected heats/test unit, etc.
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 API Spec 5L and other test reports/results
required as per this specification.

Annex - B
(Normative)
The requirement specified in API 5L Addendum 3 shall be followed with Manufacturing Procedure
Qualification test (B.5) as modified herein with first day production test:
Minimum two pipes each of completely finished pipes of first day's production from three different heats
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 test unit as per relevant clauses of this specification.
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.
First day production shall be carried out as per approved welding procedure specification. Mill parameters
established during first day shall be followed in regular production.
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 & QAP unless specified differently in this Annexure.
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 radio-graphically for the entire length. Manufacturer
has to retain films upto 5 years.
d. Product Analysis (Spectro)
Two (02) samples per pipe shall be tested for chemical analysis as per this specification.

e. Mechanical Properties
specification. Purchaser Representative will select the places in pipe from where the test specimen
shall be removed.
i. Guided Bend Test: Four (4) weld guided bend test specimen transverse to the longitudinal
weld shall be removed. Out of the four specimens, two specimens shall be used for the
face bend test and two for the root bend test.
ii. Tensile test: 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. Metallographic Examination (Macro & Micro): Six (6) weld cross-section specimen per
pipe, three (3) from each end of the pipe joint, shall be taken for metallographic
examination.
iv. Hardness Test: Two (2) samples per pipe shall be tested for hardness at room temperature
after etching. Hardness test shall be conducted on selected pipes as per requirement of
para 10.2.5 of this specification.
v. Fracture toughness test: Specimen shall be extracted as follows:

One set per pipe per temp. of three specimens each from FL, FL+2mm, FL+4mm & body
in transverse orientation shall be tested. The test shall be carried out at -25°C. Energy
values at -25°C shall be same as -20°C as per Clause no. 9.8 of this specification.
The base metal specimen shall be tested at -40°C,-25°C, 0°C & 10°C for shear area and
absorbed energy to produce full transition curve. Shear fracture area for each test shall be
at least 85% average & 75% individual, based upon a test temperature of -20oC.
vi. Drop weight tear test: One set of three test pieces per heat per temp DWTT specimens
shall be removed from base metal in a transverse direction. DWT test shall be carried out
at test temperature of -20°C.
Pipe shall be tested at temp.-40°C,-25°C, 0°C & 10°C for shear area avg. shear fracture
area shall be 85% minimum at -20°c (testing at different temperature is only to establish
transition curve) full transition curve shall be established heat out of three with a
minimum of one.
f. Burst Test:
One pipe for each size and grade on lowest thickness & higher thickness per steel supplier shall be
subjected to burst test. Burst test pressure shall be such that hoop stress generated is equivalent to
125% of SMYS (minimum). Burst test pressure & location shall be recorded. If burst pipe fails
below 125% of SMYS then manufacture shall investigate the root cause & submit the report to the
client before retesting & restarting of the regular production.

g. Cyclic Hydrotest:
Cyclic hydrotest shall be carried out for 1 hour at 50% of highest test pressure (HTP), 1 hour at
75% of HTP & 24 hours at 100% of HTP. Automatic continuous recording on the graph
(time/press.) shall be carried out. Pressure shall drop upto static head +1 bar per cycle. Test shall
be carried out one test per size per grade per lowest thickness.
h. Residual Stress Test:
One sample per heat shall be subjected to the Residual Stress test as per this specification & QAP.
i. Weldability Test:
(New)
Manufacturer shall carry out a weldability test to establish that quality girth welding meeting
various requirements mentioned in this specification can be achieved The Test shall be performed
on one pipe of each size on lowest thickness. Welding shall be carried out as per approved welding
procedure specification/ PQR of EPC contractor be joining two full length pipe with internal
clamps. All test (Tensile, test, Guided Bend test, Hardness test, Charpy test, DWTT, NDT-100%
Radiography & UT etc.) shall be performed as per this specification. Micro examination shall be
carried out as per API 1104. Welding procedure shall comply the requirements of API 1104. In
case of failure of any test results to comply the specification requirements, manufacturer shall
revise the welding procedure adopted and carry out the tests again to comply the specification
requirements. Manufacturer shall submit the test results to Purchaser to comply specification
requirements prior to shipment/ dispatch of pipes.
j. In addition, all the tests and inspections require to be conducted as per this specification, QAP &
API 5L (including Addendum-3) shall be conducted on all the pipes selected for testing during first
day production test

Annex - C
(Normative)
Repair of pipe body by welding is not permitted.
C.4.9 The defective part of the weld shall be clearly marked on the pipe so that the defect can be
(New) easily located and repaired. Approval for each repair shall be taken from TPIA before proceeding
further.
C.4.10 Following requirements shall also be complied with for repair welding:
(New)
a. Defect shall be completely removed by grinding & the same confirmed by Dye Penetrate test.
b. No repair of weld seam is permissible after cold expansion.
c. No repair of weld seam is permissible at pipe ends up to a length of 300 mm or one diameter
of pipe whichever is largest.
d. Maximum two repairs per pipe length are allowed.
e. Total length of repaired zone on each weld is limited to 5% of total weld length.
f. Distance between two repairs shall not be less than one diameter of pipe.
g. The weld repairs shall have minimum length of 100mm, even if the defect is of lesser extent.
h. An interruption of SAW is not considered as a repair unless unacceptable defects are found.
i. Repair welding on parent metal is not permitted. Only low hydrogen electrode shall be used.
j. Repair welding shall be executed only after specific approval by TPIA for each repair and to
be radiographed & Manual UT.
k. No repair of a repaired weld is permitted.
l. Repaired welds shall be inspected both by X-ray and UT.
C.4.11 The Manufacturer shall also maintain a record of repairs carried out. The records shall include
(New) repair number, pipe identification number, welding procedure applicable and NDT details.

Annex - D
(Normative)
Repair Welding Procedure
D.1 General
D.1.6 No repair of weld seam is permissible at pipe ends up to a length of 300 mm or one diameter of pipe
whichever is largest.
(New)
D.2.3 Mechanical Testing
D.2.3.2 Transverse Tensile Test
D.2.3.2.1The transverse tensile test piece shall be prepared as per API 5L. The specimen edge shall be
machined and no oxygen cut is allowed.
D.2.3.3 Transverse Guided bend test
The radius of curvature of the Jig used for guided bend tests shall be r a = 2.25t, where t is specified
wall thickness of pipe.
D.2.3.4 Charpy (CVN) impact test
The CVN impact test shall be carried out in accordance with the requirements of para 9.8 and para
10.2.4.3 of this specification.
D.2.3.5 Hardness test as specified in para 10.2.5.5 of this specification shall be included in the
(New) procedure qualification. The location of the hardness measurements is to be indicated taking into
account the new HAZ of the repaired area.

Annex - E
(Normative)
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 the annexure-P (New) of the specification.
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.
All personnel performing NDT activities shall be qualified in the technique applied, in accordance
with latest edition of ISO 11484 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.
(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).

Supervision : Level II or Level III inspector (in case evaluation
is by Level I inspector)
Note: Levels 1, 2 and 3 is ISO 11484 corresponds to levels I, II and II in ASNT SNT-TC-1A
Location of NDT equipment in the manufacturer’s facility shall be such that final inspection of
weld seam shall be performed after hydrotesting.
HR Coil Inspection
The entire width & length of each HR coil shall be 100% ultrasonically inspected by placing array
probes on the HR coil surface.
The height of indication having amplitude beyond the reference accepted signal height (100% at
80% FSH) is considered as defective indication. Locations showing indications above the
acceptance limits may be re-examined by manual ultrasonic method. Acceptance criteria,
Calibration standard & Frequency shall be as per QAP for both automatic & Manual UT.
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 50 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.
Magnetic Particle Inspection
Each pipe weld seam OD, weld seam ID & both the bevel end shall be magnetic particle inspected
as per QAP. Frequency OD weld seam shall be five pipes per shift. In case no indications are
observed in the first three shifts the frequency will be reduced to one pipe per shift.
AUT of Body & Weld seam
AUT of weld seam & body shall be as per QAP. Calibration frequency & standard shall be as per
QAP. Submerged-arc welds shall be inspected by ultrasonic methods (Refer Table E.1) using
automatic ultrasonic equipment in accordance with API Spec 5L para E.5 and as modified in this
specification. Pipe end welds shall be inspected in accordance with Para E.3.2.
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 10.2.5.3 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.
The weld at pipe ends not covered by automatic ultrasonic equipment shall be inspected by manual
ultrasonic equipment with same sensitivity and capability as automatic equipment.
In addition to the MUT confirmed indications, 0.2% of total ordered length shall be radiographed
at least at the middle of the pipe as per QAP.
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.
E.4 Radiographic Inspection of Weld Seams
E.4.2 Radiographic Inspection Equipment
E.4.2.1 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. Manufacturer has to retain films upto 5 years.
E.4.2.2 The film used for radiographic inspection of weld seam shall be class 1 or 2 as per Table 2 of
ASTM E 94 or ISO 11699-1:1998 class T2 or class T3 or ASTM E1815-06, class I or class II, and
shall be used with lead screens.
E.4.2.3 The density of the radiograph shall be not less than 2.0 and shall be chosen such that:
a) The density through the thickest portion of the weld seam is not less than 1.8.
b) The maximum contrast for the type of film used is achieved.
E.4.6 Defects found by Radiographic 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.
E.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
and probe de-coupling. 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.

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 as the pipe being inspected.
The reference standard for weld UT shall contain machined notches/holes as per Figure E.1 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 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.

a. At the beginning of each operating shift (12 hours maximum) and subsequently every 4
hours.
b. Every time there is change in probes or working condition of the UT machine.
satisfactorily in the opinion of the Purchaser's Representative/TPIA, all the pipes or skelp already
inspected after the previous verification shall be inspected again at Manufacturer's cost.

(New)
E5.5.5.1 Acceptance limits for coil, pipe body & all weld seams shall be as per QAP.

gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements shall be
recorded.
E.8.2 Ultrasonic inspection shall be used to verify that the strip or the pipe body is free of laminar
imperfections greater than those permitted by ISO 12094:1994, acceptance level B2.
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 (c) or (d).

Annexure- Q (New)
Where the inspector representing the purchaser desires to inspect pipe or witness tests, reasonable
notice shall be given of the time at which the run is to be made.
Q.2 Plant Access
The inspector representing the purchaser shall have unrestricted access, at all times while work of
the contract of the purchaser is being performed, to all parts of the manufacturer’s works that will
concern the manufacture of the pipe ordered. The manufacturer shall afford the inspector all
reasonable facilities to satisfy the inspector that the pipe is being manufactured in accordance with
this specification. All inspections should be made at the place of manufacture prior to shipment,
unless otherwise specified on the purchase order, and shall be so conducted as not too interfere
unnecessarily with the operation of the works.
Q.3 Compliance
The manufacturer is responsible for complying with all of the provisions of this specification. The
purchaser may make any investigation necessary to be satisfied of compliance by the manufacturer
and any reject any material that does not comply with this specification.
Q.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.

FIGURE: 9.13.3
X-RAY FILM
PROCEDURE FOR MEASUREMENT OF

OUT OF LINE WELD BEAD

HELICAL WELD
FIGURE: 10.2.5.5
METALLOGRAPHIC SPECIMEN EXTRACTION PLAN

- LOCATIONS WHERE HARDNESS MEASUREMENT TO BE CARRIED OUT
FIGURE: 10.2.5.6

WELD SEAM
(SHOWN STRAIGTH FOR CLARITY)
FIGURE: E.1
REFERENCE STANDARD FOR UT OF HELICAL WELD SEAM
1,2 - Longitudinal inside notch at weld seam edge

3,4 - Longitudinal outside notch at weld seam edge
5 - Transverse inside notch at weld seam edge
6 - Transverse outside notch at weld seam edge
7 - Longitudinal inside notch at weld seam centre
8 - Longitudinal outside notch at weld seam centre
9 - 1.6 mm dia. through thickness hole.

SPECIFICATION FOR JOB SPECIFICATION No.
ELECTRIC WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 1 of 26

SPECIFICATION FOR ELECTRIC WELDED (EW)

LINE PIPE (ONSHORE)
B 25.06.12 REVISED AA NR MSG
A 07.06.12 ISSUED FOR CLIENTS COMMENTS SG NR MSG

Date Purpose
No by by by

SPECIFICATION FOR ELECTRIC JOB SPECIFICATION No.
WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 2 of 26
Abbreviations:

ID Inside Diameter
EW Electric Welded

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Page 3 of 26
CONTENTS
1 SCOPE..................................................................................................................4
3 NORMATIVE REFERENCES............................................................................4
6 PIPE GRADE, STEEL GRADE AND DELIVERY CONDITION....................4
8 MANUFACTURING...........................................................................................5
9 ACCEPTANCE CRITERIA................................................................................6
10 INSPECTION.....................................................................................................11
11 MARKING.........................................................................................................15
12 COATING AND THREAD PROTECTOR.......................................................15
13 RETENTION OF RECORDS............................................................................16

(NORMATIVE)
ANNEX – C TREATMENT OF SURFACE IMPERFECTIONS AND DEFECTS

(NORMATIVE)
ANNEX-E NON-DESTRUCTIVE INSPECTION FOR OTHER THAN SOUR SERVICE

OR OFFSHORE SERVICE (NORMATIVE)
FIGURE 10.2.4.9 REVERSE BEND TEST
FIGURE E.5.2 REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD

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1. SCOPE
This specification establishes the minimum requirements for the manufacture of longitudinal
seam electric welded steel line pipe in accordance with the requirements of API (American
Petroleum Institute) Specification 5L, Forty-Fourth Edition, 2007 including Addendum-3,
July 2011 and makes restrictive amendments to API Specification 5L. Unless modified and /
or deleted by this specification, the requirements of API Specification 5L & Addendum-3
shall remain applicable.
The sections, paragraphs and appendices contained herein have the same numbering as that
of API Spec 5L (including all addendums) in order to facilitate reference. Additional
requirements, which are not specified in API Spec 5L (including Addendum-3), 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 product specification
level for line pipe to be supplied as per this specification shall be “PSL 2”.
requirements of Specification 5L, Forty-Fourth Edition, 2007 on line pipe as Product
Specification Level PSL 2.

(New)
This Specification shall be applied to line pipe of size 4½ to 16 & Grade X52 to X65.
3 NORMATIVE REFERENCES
The latest editions (editions enforce at the time of issue of enquiry) of following additional
ASTM E 112 : Standard Test Methods for Determining Average Grain Size.
Line pipe supplied to this specification shall conform to Product Specification Level PSL 2.
Following shall be applicable from Table 3 of API 5L with regards to starting material
Delivery Condition : Quenched & Tempered strip

or
Thermo mechanical-rolled strip
or
Normalized or Normalising-rolled strip
Pipe Grade : Gr. X52 to Gr. X65
6.3 Testing of raw material (steel) at steel mill shall be witness by TPIA as per steel ITP.
(New)

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8 MANUFACTURING
Type of pipe : Electric Welded
Pipe Grade : PSL 2
Starting Material : Quenched and tempered or controlled rolled or combined

rolled and accelerated cooled to impart fine grain structure to
the furnished steel or normalised/ normalising-rolled
Electric welding shall be performed with a minimum welder

frequency of 250 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
Pipe heat treatment : Normalising
Delivery condition : Q or M or N
8.3.2 Line pipe furnished to this specification shall be made from steel produced in basic oxygen or
8.3.3 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.
8.3.4 Central Slitting of coils are not permitted.

(New)
8.8.2 PSL 2 HFW Pipe
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.
8.9.2 Pipes furnished to this specification shall be non-expanded

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8.11 Jointers
8.13 Traceability
8.13.2 The manufacturer shall establish and follow procedures for maintaining heat and test unit
identity of all pipes as per requirement of API Spec. 5L and as modified in this specification.
9.2.2 The chemical composition of each heat of steel on product analysis shall be in accordance
with Table 5 and notes given below. Table 5 of API Spec 5L stands modified as below:
Table – 5: PSL 2 Chemical Requirements for Heat and Product Analyses by Percentage
of Weight

C 0.16 max. (For Grade X52 & X56)
0.12 max. (For Grade X60 & X65)
Mn 1.40 max. (For Grade 52 & X56)
1.60 max. (For Grade X60 & X65)
Si 0.15 min.
0.45 max.
S 0.015 max.
P 0.02 max.
Al 0.07 max.
Cr 0.20 max.
Mo 0.10 max. (For Grade X52 to X65)
Cu 0.35 max.
Ni 0.20 max.
N 0.012 max.
B 0.0005 max.
Note: m (New)
i. V+Nb+Ti shall not exceed 0.12% (for Grade X52 to X65)
Note: n (New)
If alloying elements other than those specified in Table 5 above are added to the steel, the
limits of the additional components shall be agreed with the Purchaser.
Note: o (New)
Minimum for “Si” is not applicable for Al killed steel.
CEPCM 0.20 %

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Boron content shall be considered in CEPCM formula even if it is less than 0.0005%.
CE IIW 0.40 %
The CE IIW limit shall not apply if C≤0.12%

(New)
For heat analysis and product analysis, all the elements listed in Table 5 of this specification
shall be analysed and reported, even if those are not purposely added but are present as
residuals only.
9.3.2 The finished pipe (after all heat treatment operations) shall conform to the requirements of
Table 7 of API Spec 5L and as modified herein.
X52 to X65 21,700 (149.6)
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 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 (f) of Table-7. However elongation in no case shall be less than 25%.
9.6 Flattening test
Dye penetrant testing may be used to positively confirm the presence of crack, break or
opening.
Acceptance criteria for flattening test shall be as follow:

The pipe shall be Flattened to ½ original OD without weld opening, continue flattening to 1/3
of specified OD without cracks other than in weld and continue flattening until opposite wall
of pipe meet and no lamination on material on full flat.
Flattening test shall be carried out before and after hydro test for first day production test in
two samples (0° & 90°) per pipe combination of size & wall thickness.
Frequency of flattening test during regular production shall be as per QAP. Four (2 samples
each from first & last accepted pipe of the coil) samples per coil per combination of pipe size
& wall thickness. In case of weld stop one sample from each crop end shall be tested at 0° &
90°.

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The Charpy V notch impact test shall be carried out at (-) 20ºC & 0 ºC. The minimum all heat
average full size absorbed energy value (based on a set of three specimens) for transverse
body specimen, weld and HAZ shall be as per below table.

Test temp.
(-) 20ºC 35 J 28 J 27 J 22 J
0ºC 100 J 80 J 40 J 32 J
In addition the lowest individual absorbed energy value of the three specimens shall not be
less than 80% of the value specified for body, weld and HAZ.
9.8.1.1 The specimen shall be full 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.
9.8.2.2 For pipes of all sizes and wall thicknesses, the minimum (set of three test pieces) shear
fracture area for each test shall be at least 85% average & 75% individual, based upon a test
temperature of -20oC(-4°F).
(New) (-) 20ºC.
9.10.1.2 Cracks, Sweats and Leaks are not acceptable.
9.10.3 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 (c) or (d) of E10 (Annex-
E). 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 10.2.5.4 (New) of this specification.
9.10.4 Lamination
Any lamination or inclusion either extending into the face or face of bevel & pipe body with
in manual UT portion or present within 50mm from pipe ends is considered defect and pipe
The disposition of lamination and other type of defects on the skelp/pipe shall be as per
Annex-E of API Spec 5L and as modified in this specification.
9.10.5.2 Dents
Allowable dent size shall be as per API Spec 5L and as modified in this specification.
Disposition of dents shall be carried out in accordance with clause (c) or (d) of E10 (Annex-
E) of API Spec 5L.

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a) Dent, 3.2 mm sharp bottom gouges are not acceptable.

9.10.6 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.
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 disposed-off in
accordance with clause C.3 and as modified in this specification.
9.11.1.2 This specification shall be applied to line pipe of size 4 ½” to 16” (both size included).
9.11.3.1 Diameter
Tolerance for diameter and out-of-roundness shall be as under and Table 10 of API Spec 5L
stands modified accordingly.
Diameter Tolerance
Pipe Body
The outside diameter of pipe body, as determined by taping the circumference, shall not
deviate by more than the values given below.
Size Tolerance
4 ½ and ≤ 16 0.75% of specified OD or 2 mm whichever is small
Pipe Ends
Diameter tolerances for the pipe ends indicated in API Spec 5L, Table 10 shall be applicable
on the inside diameter for pipe size 14” and on outside diameter for pipe size ≤ 12”.
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/ISO 3183. Inside diameter
is defined as ID = (OD-2WT.) where ID, OD & WT are the inside diameter, specified outside
diameter and specified wall thickness respectively.
Pipe Body
Out of roundness on pipe except the end, shall not exceed the following:

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Size Tolerance
4 ½ and ≤ 16 : 3 mm (within 100 mm from both the ends)
Pipe End
Out of Roundness i.e., the difference between the maximum and minimum diameter (inside
of pipe size 14” and on outside for pipe size ≤ 12”) at pipe ends, shall not exceed the
following:
Size Tolerance
≤ 10 ¾ : 2 mm
12 ¾ : 3 mm
Out of roundness tolerance indicated in API Spec 5L, Table 10 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.
tolerances shall be measured and recorded at least 3 times per operating shift (12 hrs.
maximum).
The tolerances on specified wall thickness shall be (+) 10% and (-) 0%. API Spec 5L, Table
11 stands cancelled.
9.11.3.3 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 pipe from which samples are cut
for testing. The minimum average length of the entire ordered quantity in any case shall be
12.0m. API Spec 5L, clause no. 9.11.3.3 & Table 12 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.
The total deviation from a straight line over the entire pipe length for all pipe sizes shall not
exceed 10 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).
The local deviation from a straight line at each pipe end (1000 mm portion) specified in
clause ‘b’ shall not be allowed.

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9.12.5 Plain Ends
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 9.11.3.2 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
(New) 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.
9.13.1 Radial Offset of Strip / 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).
9.13.2 Height of the flash or weld bead / reinforcement
All pipes shall be checked for conformance of height of flash (+0.7 mm, - 0 mm) and shall be
10 INSPECTION
10.2.1.2 The frequency of Inspection and testing shall be as per QAP document no. A286-000-11-42-
QAP-0005.
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.
Product Analysis:
Two samples per test unit shall be analysed. The test unit shall be 50 pipes per heat per size.
Pipes selected shall be such that one at the beginning of the heat and one at the end of the
heat are also represented.
Tensile Test Frequency (For Pipe body & Weld):
Tensile tests shall be made at the frequency of two (02) set per inspection test unit per heat
per size as per QAP. Set shall consist of two samples one for weld one for body:
thickness by the same process, from the same heat and under the same manufacturing
conditions.

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Charpy Impact Test:
The minimum test frequency shall be one set per 100 pipes per heat per temp. per
combination of pipe size and specified wall thickness. The set shall consist of three
specimens each from Body, FL, FL+2mm FL+4mm in transverse direction.
Metallographic Examination:
Longitudinal weld, from one finished pipe from each test unit of 50 pipes per heat or at least
once per operating shift (12 hrs maximum) and whenever changes of grade, diameter or wall
thickness are made and whenever significant excursions from operating heat treatment
conditions are encountered.
The Hardness test shall be conducted for 1 sample per 50 pipes per heat during regular
production.

Visual inspection, pipe diameter & out of roundness, wall thickness, pipe weight, length etc.
as per API 5L and as modified in this specification. All dimensions and tolerances shall be
measured and recorded at least three times per operating shift (12 hrs max.)
API 5L Table 18 of Addendum-3 shall be considered applicable for the tests which are
not covered in this specification.
10.2.3 Samples and test pieces for mechanical tests
Sample 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.
Longitudinal tensile tests shall be carried out on a strip specimen.
For weld tensile test 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.
10.2.3.3 Test piece for CVN Impact test
In addition to the specimen taken from the body of the pipe, three transverse specimens each
from FL, FL+2mm, FL+4 mm shall also be taken. When either full size or sub-size
transverse specimen as per API Spec 5L, Table 22 is not possible to obtain, transverse
specimen of either ⅓ Size or ¼ 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 9.8.1.1 and as modified in this
specification.

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10.2.4 Test methods
radius shall be 8 mm.
10.2.4.9 Reverse Bend Test

(New)
a) Reverse bend test shall be executed with the same number of tests and retests specified for
flattening test in para 10.2.4.7 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. 10.2.4.9 of this specification.
Reverse bend test shall be carried out before & after hydrotest for first day production. The
test frequency shall be 2 samples per pipes per combination of size & wall thickness as per
QAP.
For Regular production two samples per coil per combination of pipe size & wall thickness
from the first & last accepted pipe as per QAP. In case of weld stop one sample each from
crop end shall be tested as per QAP.
b) 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:
1.4 ( D – t ) t
A= 2R= -t
e ( D – 2 t ) – 1.4 t
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
X-52 0.1250
X-65 0.1100
c) 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 600
(Ref. Fig 10.2.4.9 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 600 the
mandrel shall be plunged into the specimen until opposite walls of the specimen meet.
d) 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 penetrant testing may be used to positively confirm cracks or
openings.

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10.2.5 Macrographic and metallographic tests
10.2.5.5 A test specimen for metallographic & hardness examination shall be taken transverse to the
(New) longitudinal weld, from one finished pipe from each test unit 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 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 in case imperfections or defects are observed, it will
become a cause for re-evaluation of welding parameters as deemed necessary by Purchaser's
Representative.
10.2.5.6 Vickers hardness tests shall be carried out on each specimen taken for metallographic
(New) examination in accordance with ASTM E-92, at locations indicated in Fig. 10.2.5.6 of this
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 of API Spec. 5L.
10.2.5.7 In Metallographic test, no untempered martensite remains & uniformly distributed ferritic
(New) structure shall be established and fusion line shall be clearly visible. The grain size shall be 7
or finer as per ASME E 112.
10.2.6.1 Test pressure shall be held for a minimum period of 15 seconds for all sizes and grades of
pipes. Each pipe shall be hydrostatically tested during both regular & first day production.
maximum range of 4 times the test pressure. The pressure gauge shall be calibrated by means
of a "Dead Weight" tester only.
generated is equivalent to 100% of SMYS, computed based on the formula mentioned in API
Spec 5L Para 10.2.6.5.
10.2.6.8 Calibration of pressure gauge shall be done at start of an each shift (12 hours max.) &
(New) calibration of hydrotester with 1.6 mm TDH shall be carried out at beginning of shift.
10.2.7 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.
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.
10.2.8.6 In addition to API requirements, the measuring equipment requiring calibration or

verification under the provisions of API Spec 5L shall be calibrated with manual instruments

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at least once per operating shift (12 hours maximum). Such calibration records shall be
furnished to Purchaser’s Representative on request.
This para stand Cancelled.
10.2.12 Retesting
Modalities of recheck analysis shall be as per API Spec. 5L (Addendum -3) as applicable to
the test unit being tested (refer para 10.2.1.2 of this specification). However, during
individual testing, each pipe shall be fully analysed to meet the requirements of Table 5 of
this specification.
11 MARKING
applicable.
number and weight.
- 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.
- 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.
- 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.
internal surface at opposite end. Bar coding procedure shall be submitted for
owner/TPIA approval. Radio frequency identification (RF-ID) shall be provided for
all bare pipes.
12 COATING AND THREAD PROTECTORS
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.

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In addition to the records indicated in clause 13 of API Spec 5L, 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.

production report in English language indicating at least the following for each pipe.
International System of units (SI) shall be adopted.
- Pipe number
- 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:
- Data on test failures, rejected heats/test unit, etc.
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 API Spec 5L and other
test reports/results required as per this specification.

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Annex - B
(Normative)
The requirement specified in API 5L (Addendum-3) shall be followed with Manufacturing

Procedure Qualification Test (B.5) as modifies herein with first day production test.
Minimum two pipes each of completely finished pipes of first day's production from three different
heats 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 test unit as per relevant clauses of this
specification.
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.
First day production shall be carried out as per approved welding procedure specification. Mill
parameters established during first day shall be followed in regular production.
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.
b. NDT Inspection
The weld & body of all pipes shall be examined ultrasonically by automatic ultrasonic
equipment. In addition the manual UT, MPI & X ray shall be carried out as per this
specification & QAP.
c. Mechanical Properties
specification. Purchaser Representative will select the places in pipe from where the test
specimen shall be removed.

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i. Two (2) flattening test specimen per pipe shall be removed; one specimen shall be
tested with weld at 0 and other at 90 . The Test shall be carried out before & after
the hydrotest of the first day production.
ii. Two (2) set per pipe (set shall consist of two transverse specimen) each for base
metal & weld for tensile test shall be tested. In case transverse base metal specimen
is not applicable as per Figure-5 b of API Spec 5L, longitudinal specimen may be
taken.
iii. Six (6) weld cross-section specimen per pipe, three (3) from each end of the pipe
joint, shall be taken for metallographic examination.
iv. Two (2) sample per pipe shall be tested for hardness at room temperature after
etching. Hardness test shall be conducted on selected pipes as per requirement of
para 10.2.5 of this specification.
v. Fracture toughness testing specimen shall be extracted as follows:
One set per pipe per temp. of three specimens each from FL, FL+2mm, FL+4mm &
body in transverse orientation shall be tested. The test shall be carried out at -
25°C.Energy values at -25°C shall be same as -20°C as per Clause no. 9.8 of this
specification.
The base metal specimen shall be tested at -40°C,-25°C, 0°C & 10°C for shear area
and absorbed energy to produce full transition curve. Shear fracture area for each
test shall be at least 85% average & 75% individual, based upon a test temperature
of -20oC.
vi. Reverse bend test shall be carried out before & after hydrotest for first day
production. The test frequency shall be 2 samples per pipes per combination of size
& wall thickness as per QAP.
e. One pipe of lowest thickness per grade per size per steel supplier shall be subjected to burst
test. Burst test pressure shall be such that hoop stress generated is equivalent to 125% of
SMYS (minimum). Burst test pressure & location shall be recorded. If burst pipe fails below
125% of SMYS then manufacture shall investigate the root cause & submit the report to the
client before retesting & restarting of the regular production.
f. Cyclic hydrotest shall be carried out for 1 hour at 50% of highest test pressure (HTP), 1 hour
at 75% of HTP & 24 hours at 100% of HTP. Automatic continuous recording on the graph
(time/press.) shall be carried out. Pressure shall drop upto static head +1 bar per cycle. Test
shall be carried out one test per size per grade per lowest thickness.
g. In addition, all the tests and inspections require to be conducted as per this specification,
QAP & API 5L (including Addendum-3) shall be conducted on all the pipes selected for
testing during first day production test.

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 19 of 26
Annex - C
(Normative)
Repair of defects by welding is not permitted.

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 20 of 26
Annex - E
(Normative)
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 the Annex-Q (New) of
the specification. 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.
All personnel performing NDT activities shall be qualified in the technique applied, in
accordance with latest edition of ISO 11484 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.
(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).

Supervision : Level II or Level III inspector (in case
evaluation is by Level I inspector)
Note: Levels 1, 2 and 3 is ISO 11484 corresponds to levels I, II and III in ASNT SNT-TC-1A
Location of NDT equipment in the manufacturer’s facility shall be such that final inspection
of weld seam of pipe shall be performed after hydrotesting.
HR Coil Inspection
The longitudinal edges of the HR coil shall be 100% ultrasonically inspected over a width of
at least 25 mm from the trimmed HR coil edge. Remaining HR coil 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 HR coil surface uniformly spread over the
area.
Alternatively the pipe may be tested after welding of longitudinal seam by rotary ultrasonic
testing of the pipe body. The coverage area shall be 100%. For reference standard to be used
for rotary ultrasonic testing shall be that of reference standard of weld seam.
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.

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 21 of 26
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 50 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. For the pipes
previously subjected to 100% rotary ultrasonic inspection, the above requirement shall not
apply.
AUT of body & weld
AUT of body & weld shall be as per QAP, The reference standard, calibration frequency &
acceptance criteria shall be as per QAP.
Bevel Inspection
Bevel face & 100 mm from both the end of all pipes shall be inspected by magnetic particle
method to detect defects. Acceptance criteria shall be as per QAP
Radiography (X-Ray)
The weld of the pipe shall be inspected by X-Ray method to detect defects as per API 5L. For
first day production the frequency shall be 0.1% of each pipe of total weld length. During
Regular production the frequency shall be 0.1% of the total weld length.
Weld Inspection
Electric welds shall be inspected by ultrasonic methods (Refer Table E.1) using automatic
ultrasonic equipment in accordance with API Spec 5L para E.5 and as modified in this
specification. Pipe end welds shall be inspected in accordance with Para E.3.2.
Eddy current Test
The eddy current examination shall be carried out on each pipe for detecting significant
imperfections during first day and regular production. Reference standard shall be one
“2.5mm radially drilled hole” at the center. Calibration shall be performed twice in the shift
(12 hours).
Each pipe ends not covered by automatic ultrasonic equipment, untested portions &
suspected areas which are marked by AUT shall be inspected by manual ultrasonic
equipment with same sensitivity and capability as automatic equipment.
E.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 and probe de-coupling. 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.

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 22 of 26

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 as the pipe being inspected.
The reference standard for weld UT shall contain machined notches/holes as per Figure E.5.2
of this specification and as given below:
- One longitudinal inside notch of type N 10 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
6mm 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 ¼ inch dia FBH x ½ t depth, where‘t’ is the specified wall thickness.
a. At the beginning of each operating shift (12 hours maximum).

b. At every four hours during each operating shift (12 hours maximum).
Or
Every 50 pipes whichever is earlier.
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.

(New)
E5.5.5.1 Acceptance limits for coil, pipe body & weld shall be as per QAP.
gauss when measured with Hall-effect gaussmeter. All residual magnetism measurements
shall be recorded.
E.8.2 For EW pipe, ultrasonic inspection shall be used to verify that the strip/plate or the pipe body
is free of laminar imperfections greater than those permitted by ISO 12094:1994, acceptance
level B2.
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 (c) or
(d).

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 23 of 26
Annex- Q (New)
Where the inspector representing the purchaser desires to inspect pipe or witness tests,
reasonable notice shall be given of the time at which the run is to be made.
Q.2 Plant Access
The inspector representing the purchaser shall have unrestricted access, at all times while
work of the contract of the purchaser is being performed, to all parts of the manufacturer’s
works that will concern the manufacture of the pipe ordered. The manufacturer shall afford
the inspector all reasonable facilities to satisfy the inspector that the pipe is being
manufactured in accordance with this specification. All inspections should be made at the
place of manufacture prior to shipment, unless otherwise specified on the purchase order, and
shall be so conducted as not too interfere unnecessarily with the operation of the works.
Q.3 Compliance
The manufacturer is responsible for complying with all of the provisions of this specification.
The purchaser may make any investigation necessary to be satisfied of compliance by the
manufacturer and any reject any material that does not comply with this specification.
Q.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.

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 24 of 26
FIGURE: 10.2.4.9
REVERSE BEND TEST

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 25 of 26
FIGURE: 10.2.5.6

WELDED (EW) A286-000-11-42-SP-0005 Rev. 0
LINE PIPE (ONSHORE)
Page 26 of 26
1 - Longitudinal inside notch (N10) at weld line

2 - Longitudinal outside notch (N10) at weld line
FIGURE: E.5.2
REFERENCE STANDARD FOR UT OF LONGITUDINAL WELD

DOCUMENT No.
PROCEDURE FOR APPLICATION
OF BARCODE ON LINE PIPES A286-000-11-42-SP-0006 Rev. 0
Page 1 of 5
esglkukµHkfBaMk ikbiykbu ifj;¨tuk

MEHSANA – BATHINDA PIPELINE PROJECT
PROCEDURE FOR
APPLICATION OF BAR CODE ON LINE PIPES
0 04.09.12 Issued for Bids SYG SRG MSG

Date Purpose
No by by by
DOCUMENT No.
Page 2 of 5
CONTENTS
1.0 PURPOSE…………………………………………………………….………3
2.0 SCOPE……………………………………………………………… ….…….3
3.0 METHOD………………………………………………… …………….……3
3.1 PROCEDURE FOR BAR CODING OF BARE LINE PIPE AND

EXTERNALLY COATED HSAW / LSAW / ERW LINE
PIPE.……………………………………………………………… ………….3
3.1.1 ON BARE/EXTERNAL 3LPE COATED PIPES… …….… 3
3.1.2 PRINTING OF BARCODE LABELS…………………… ...4
3.1.3 FIXING OF LABELS ON PIPE………………………… ….5
3.1.4 VARIFICATION OF BARCODE LABELS……………… 5
3.1.5 SCANNING OF BARCODES…………………………… ….5
DOCUMENT No.
Page 3 of 5
1.0 PURPOSE:-
THE PURPOSE OF THIS SPECIFICATION IS TO ENSURE THE IDENTIFICATION

OF PIPES THROUGH BARCODE LABEL.
2.0 SCOPE:-
This procedure defines to identify the pipes through barcode label scanning. This
procedure covers the application of 2D type bar code and pipe marking on Bare Pipe
and 3LPE coated pipes after the final coating of bare pipes. Bar code to be applied
after clearance from TPIA upon final acceptance of external coated pipes/Bare pipe.
Barcode should have pipe NO. Type (3LPE/ERW), Coat No., Dia., Unit, Length, Wall
thickness, heat No. and item code. TPIA shall verify barcode with hand held reader
during inspection of pipe.
EPC contractor to supply one barcode reader for each dumpsite.
3.0 METHOD:-
3.1 PROCEDURE FOR BAR CODING OF BARE LINE PIPE AND EXTERNALLY
COATED HSAW / LSAW / ERW LINE PIPE.
3.1.1 ON BARE / EXTERNAL 3LPE COATED PIPES
Pipe marking (stencil) shall be made from both end of the pipe opposite to the weld
line. Pipe no shall be printed on barcode at the bottom. VENDOR has to ensure
physical correction of the pipe as per stencil & barcode before applying barcode. One
2D type barcode sticker shall be pasted at an angle of 180° from the stencil side at a
distance of 200 mm from the cutback area.
1. For details refer annexure–I for pipe marking and bar coding procedure on the
outside pipe surface.
2. In case any unfit pipes found for coating or for any reason pipes are cut, the
actual length of pipe shall be given in barcode sticker.
3.1.2 PRINTING OF BARCODE LABELS
The barcode labels will be printed at the time of final inspection (label size 2”x 4”) and
will be printed by using printer. The pipe number and other details will be taken from
the Final Visual and Dimension inspection report system. The label shall have details
as per Client/TPIA. The barcode and item code as per sample attached. The label
details contains PIPE No, Coat No .ASL No, Item Code up-to 10 Digit Max.
DOCUMENT No.
Page 4 of 5
SAMPLE PIECE OF BARCODE LABEL
PIPE NO : XXXXXXXXXX
TYPE : 3LPE/ERW
HEAT NO : XXXXXXX 02”
COAT NO : XXXXXXXXXX
DIA : XX INCH
LENGTH : 12.05 M
W. THICKNESS : XX MM
ITEMCODE : XXXXXXXXXX
04”
The barcode standard is symbology and the paper material used is 2D and tear-able.
3.1.3. FIXING OF LABELS ON PIPES
Ensure that the surface area in which labels are pasted should be clean, dry and free
from dust. For each pipe four (4) labels shall be fixed, two for each end at one
inside & one out side (fixed approx. 200 mm from the cutback / bevel area and 180°
on each end). All bar code shall be oriented perpendicular to the weld seam. The
barcode label shall be put on completely finished pipe. Barcode label should not be
overlapped with stencilling or any other marking outside coated pipe. (i.e. external
coated pipe surface)
3.1.4. VERIFICATION OF BARCODE LABELS
At the time of dispatching of pipes, QC personnel shall verify the barcode labels
visually. If the barcode labels found damaged, missing or illegible for the purpose
same shall be replaced by new one and applied as described in clause 3.1.1 & 3.1.2
3.1.5. SCANNING OF BARCODES
The barcode can be read by scanning the codes by scanner provided by supplier at
pipe mill and site. When the code is scanned the pipe number will be visually seen
on the scanners monitor and same will be saved in its memory. The full details of
the pipe can be obtained by connecting the computer with the scanner having
database for these pipes.
1. First connect the scanner to the computer.
a. One cable from CPU to scanner

b. Second cable from power line to scanner for charging.
DOCUMENT No.
Page 5 of 5
2. Make the data file in which details of the pipes are available.
3. Copy the data file and paste in the scanner.
4. The data will be loaded in scanner
5. Scan the barcode by scanner.
6. If the code matches with the available data in the scanner , it shows all the
details of the barcode.
7. Scanner also shows the number of the data available in scanner and out of
which how many are scanned.
8. If the data scanned does not matches with the available data, the scanner
Shows NA i.e. Not Available.
ANNEXURE –I (OUTSIDE SURFACE –ON EXTERNAL COATED PIPE)
DOCUMENT No.
RFID SPECIFICATION
FOR LINE PIPES AND VALVES A286-000-11-42-SP-0007 Rev. 0
Page 1 of 3

RFID SPECIFICATION
FOR LINE PIPES AND VALVES

Date Purpose
No by by by
DOCUMENT No.
RFID SPECIFICATION
Page 2 of 3
SCOPE
This specification defines the minimum technical requirements of RFID (Radio

Frequency Identification) for supply and application of mandatory spare item for all
size & type of Valves & line Pipes in Mehsana Bathinda Pipeline projects of GIGL.
EPC contractor to supply one RFID Reader per Pipeline section.
RFID APPLICATION
RFID shall be applied on coated line pipes (If line pipes are bare then tag should be
applied on bare line pipes) and valves.
RFID system should able to capture all necessary line pipe & valve data.
RFID Tag manufacturer should able to provide label usage certificate for 5 year from
end user customer. Tag should be robust to withstand dirt, temperature, rain,
scratches etc.
Reader range shall be good enough to read the data easily after piling/storage of
Valves.
Storage of Line pipe/Valves is in open environment and hence reader should read the
tag in darkness as well as in sunlight environment.
Software and hardware shall be scalable, maintainable and reusable as per GIGL
requirement and desecration.
Any data coming to the system shall be capture directly from manufacturer’s system
data base. System shall be designed in such a manner that no one can enter data
manually in between.
Sample specification for reader and RFID tags are as per attached Appendix-1,
however vender has to submit technical specification of hardware and shall take
approval for hardware and software supplier from GIGL.
RF ID tag agency who had successfully completed one assignment for oil and gas
industry can be considered as suitable and to be proposed for owner’s approval by
successful vendor after award of the job.
DOCUMENT No.
RFID SPECIFICATION
Page 3 of 3
Appendix-1
RFID Reader Technical Specs
Parameter RRUHFHH1
Operating Frequency 865 to 868 MHz
Power Supply 5 V / 3 A DC Adapter
Antenna External Antenna
Main Battery Lithium lon 3.7V, 4400mAh, (Rechargeable)
CPU Intel Bulverde PXA270, 520 MHz processor
Transmitting Power 500mW max.
Read Range Laboratory rang 8 to 10 m and metallic environment

Communication Interface minimum
USB / Ethernet to 2 m*
/ Wireless
Supported Transponders ISO 18000-6C
Indicators Touch screen Display, Buzzer

Operating Temperature -20 C to +50 C
Storage Memory Up to 2 GB
Weight 380 gms approx.
Dimensions 17.5cm L x 7.4cm W x 2.3cm (3.2cm) H
RFID Tag Technical Specs
Parameter RRUHFT01
Operating Frequency 865 to 868 MHz
Antenna Single / Dual Dipole
Data Retention 10 Years Minimum

Antenna Material Aluminum
EPC Memory 96 bits
User Memory Up to 1024 bits
Operating Temperature -10°C to +70°C
Dimensions Available in various dimensions and shapes
SPECIFICATION FOR PIPELINE JOB SPECIFICATION No.
BALL VALVES (ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 1 of 14

SPECIFICATION FOR PIPELINE BALL VALVES

(ONSHORE)
B 09.08.12 REVISED & RE-ISSUED AS JOB SPECIFICATION AA NR MSG

Date Purpose
No by by by

JOB SPECIFICATION No.
SPECIFICATION FOR BALL VALVES
(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 2 of 14
CONTENTS
1.0 SCOPE ........................................................................................................................................ 3
2.0 REFERENCE DOCUMENTS .................................................................................................... 3
3.0 MATERIALS .............................................................................................................................. 4
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS ............................................................. 4
5.0 INSPECTION AND TESTS ....................................................................................................... 8
6.0 TEST CERTIFICATES ............................................................................................................. 11
7.0 PAINTING, MARKING AND SHIPMENT ............................................................................ 11
8.0 SPARES AND ACCESSORIES ............................................................................................... 12
9.0 DOCUMENTATION ................................................................................................................ 12
FIGURE-4.9 .......................................................................................................................................... 14

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 3 of 14
1.0 SCOPE
This specification covers the minimum requirements for design, manufacture, testing and
supply of low temperature carbon steel ball valves of size DN 50 mm (2") and above and
ANSI pressure rating Class 150# thru 600# for use in onshore pipeline systems handling non-
sour hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
2.0 REFERENCE DOCUMENTS
2.1 All valves shall be manufactured and supplied in accordance with the American Petroleum
Institute (API) Specification 6D, Twenty Third edition, April 2008 / ISO 14313:2007,
Petroleum and Natural Gas Industries – Pipeline Transportation Systems – Pipeline valves,
with additions and modifications as indicated in the following sections of this specification.
2.2 Reference has also been made in this specification to the latest edition (edition enforce at the
time of issue of enquiry) of the following Codes, Standards and Specifications.
ASME B31.3 - Process Piping.
ASME B31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids.
ASME B31.8 - Gas Transmission and Distribution Piping Systems.
ASME B16.5 - Steel Pipe Flanges and Flanged Fittings.
ASME B 16.10 - Face-To-Face and End-To-End Dimensions of Valves.
ASME B 16.25 - Butt-welding Ends.
ASME B16.34 - Valves - Flanged, Threaded and Welding Ends.
ASME B16.47 - Large Diameter Steel Flanges.
API 1104 - Welding Pipelines and Related Facilities.
ASME Sec VIII - Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Sec IX - Boiler and Pressure Vessel Code - Welding and Brazing
Qualifications
ASTM A-370 - Standard Test Methods and Definitions for Mechanical

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

Connecting-end Flanges of Valves and Fittings.
MSS-SP-44 - Steel Pipeline Flanges.
SSPC-VIS-1 - Steel Structures Painting Council Visual Standard.
SIS 055900 - Pictorial Surface Preparation Standards for Painting Steel

Surface (Swedish standard)

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 4 of 14
2.3 In case of conflict between the requirements of this specification, API 6D and the Codes,
Standards and Specifications referred in clause 2.2 above, the requirements of this
specification shall govern.
3.0 MATERIALS
3.1 Materials for major components of valves shall be as indicated in Valve Data Sheet. Other
components shall be as per Manufacturer's standard (suitable for the service conditions
indicated in Data Sheet) and shall be subject to approval by Company. In addition, the
material shall also meet the requirements specified hereinafter.
All process-wetted parts, metallic and non-metallic, and lubricants shall be suitable for the
service specified by the Company. Manufacturer shall confirm that all wetted parts are
suitable for treated water/seawater environment, which may be used during field testing.
Non-metallic parts of the valves (including O-rings, soft seals etc.) intended for hydrocarbon
gas service shall be resistant to explosive decompression.
3.2 Carbon steel used for the manufacture of valves shall be fully killed.
3.3 The ratio of body yield strength and body ultimate tensile strength of each test valve on which
body yield strength and body ultimate tensile strength are determined, shall not exceed 0.90.
3.4 The carbon equivalent (CE) of valve end connections which are subject to further field
welding by Company shall not exceed 0.43 on check analysis for each heat of steel used, as
calculated by the following formula:
Mn Cr + Mo +V Ni + Cu
CE = C + + +
6 5 15
3.5 Charpy V-notch test on each heat of base material shall be conducted as per API 6D-Clause
8.5, for all pressure containing parts such as body, end flanges and welding ends as well as
bolting material for pressure containing parts. The Charpy V-notch test requirements of
applicable LTCS material standard shall be conducted.
In addition to above the Charpy V-notch test shall be conducted at -20°C. Test procedure shall
conform to ASTM A 370. The average absorbed energy value of three full sized specimens
shall be as per 35 J. The minimum impact energy value of any one specimen of the three
specimens analysed as above, shall not be less than 28 J.
3.6 Hardness test shall be carried out as per ASTM A370 for each method of manufacture and
each heat of steel used in the manufacture of valves. A full thickness cross section shall be
taken for this purpose and the maximum hardness of the materials of valve components shall
not exceed 248 HV10.
3.7 In case of LTCS Ball material, the ball shall have 75 micrometers thick electroless nickel
plating (ENP) as per ASTM B733 with SC 2, Type II, and Class 2. The hardness of plating
shall be min. 50 RC.
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS
4.1 Valve design shall meet the requirements of API Specification 6D and shall be suitable for the
service conditions indicated in the Valve Data Sheet. The ASME Boiler & Pressure Vessel
Code, Section VIII, Division 1 shall be used to design the valve body. Allowable stress

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 5 of 14
requirements shall comply the provisions of above code. In addition, corrosion allowance
indicated in Valve Data Sheet shall be considered in valve design. The manufacturer shall
have valid license to use API monogram on valves manufactured as per API 6D.
4.2 For above ground valves, body design shall be either fully welded or bolted type. For buried
valves, valve body design shall be fully welded type only. Valve body joints with threads are
not permitted. In the valve body outlets also threading is not permitted.
4.3 Ball shall be of single piece, solid type construction.
4.4 All ball valve shall be Full bore (FB) as per data sheet(s). Reduced Bore (RB) valves shall not
be permitted. Full bore valves shall be suitable for the passage of all types of pipeline pigs
including instrumented intelligent pigs and regular cleaning, batching and scraper pigs on
regular basis without causing damage to either the valve component or the pig. The full bore
valve shall provide an unobstructed profile for pigging operations in either direction. Full bore
valves shall be designed to minimize accumulation of debris in the seat ring region to ensure
that valve movement is not impeded.
4.5 Ball mounting shall be trunnion or pivot type only for all valves of size 2” and above. Valve
design shall minimize the possibility of debris ingress into the trunnion as far as practicable.
4.6 For valves with primary metal to metal contact and secondary soft seats, O-rings or other seals
if used for drip tight sealing shall be encased in a suitable groove in such a manner that it can
not be removed from seat ring and there is no extrusion during opening or closing operation of
valve at maximum differential pressure corresponding to valve class rating. The seat rings
shall be so designed as to ensure sealing at low as well as high differential pressures.
For soft seated valves seat rings may be provided with soft insert. The same shall be positively
locked in position. All such ball valves shall comply fire safe design and qualified by fire
testing as per API 6FA specification for Fire Test for Valves.
4.7 Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar
in both open and closed positions.
4.8 Valves shall have double block and bleed feature to facilitate complete flush, drain and
venting of the valve body cavity. Valves shall have antistatic feature and antistatic test as per
BS EN 17292/ API 6D. Valves shall be provided with anti blowout proof arrangement as per
BS EN 17292 / API 6D
4.9 Full Bore valves of nominal valve size DN 200 mm (8”) & above shall have provision for
secondary sealant injection under full line pressure for seat and stem seals. All sealant
injection connections shall be provided with a block valve and internal non-return valve.
Valve design shall have a provision to replace the sealant injection fitting under full line
pressure. Location and arrangement of sealant point shall be as per Fig. 4.9.
4.10 Valves shall be provided with vent and drain connections. Location and arrangement of vents
and drains shall be as per Fig. 4.9. Body vent and drain shall be provided with valves (Ball or
Plug type). Number and size shall be as per Fig. 4.9.
4.11 Valve design shall ensure repair of stem seals/packing under full line pressure.
4.12 Full Bore valves of nominal valve size DN 200 mm (8") & above shall be equipped with
support foot and lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs.
Height of support foot shall be kept minimum. The location and size of support foot/lifting
lugs shall ensure unrestrictive operation of vent/drain valves.

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 6 of 14
4.13 Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high
alloy steel components. Suitable insulation shall be provided as required.
4.14 For valves to be used in liquid service, the body cavity over-pressure shall be prevented by
self-relieving seat rings/assemblies. Self-relieving seat rings shall relieve at a body cavity
differential pressure not exceeding 50% of the valve class rating pressure.
4.15 a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt
welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged
body valves shall be integrally cast/forged with the body of the valve. Face to face/end
to end dimensions shall conform to API 6D. Face-to-face and end-to-end dimensions
for valve sizes not specified in API 6D shall be in accordance with ASME B 16.10.
Face-to-face and end-to-end dimensions not shown in API 6D or in ASME B 16.10
shall be as per Manufacturer Standard and shall be subject to approval by Company.
b) Flanged ends, if specified, shall have flanges as per ASME B16.5 for valve sizes upto
DN 600 mm (24”) excluding DN 550 mm (22”) and as per MSS-SP-44/ASME B
16.47 Series A for valve sizes DN 550 mm (22”) and for DN 650 mm (26 inches) and
above. Flange face shall be raised face as indicated in Valve Data Sheet. Flange face
finish shall be serrated or smooth as indicated in Valve Data Sheet.
c) Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe to
which the valve has to be welded shall be as indicated in the Valve Data Sheet. In case
difference exists between thickness of welding ends of valve and connecting pipe, the
welding ends of valve shall have bevel preparation as per ASME B31.4 or ASME
B31.8 as applicable.
4.16 Design of weld end valves shall be such that during field welding operations, the soft seals or
plastic components of the valve (where ever used) is not liable to be damaged. The
manufacturer shall furnish necessary field welding instructions and post-weld test procedure
to demonstrate integrity and leak-tightness of valves after field welding operations.
4.17 PUP pieces of Butt weld end valves:
a) Butt welded end valves shall be supplied with pup pieces on either side of minimum
length of 150 mm for sizes up to 8” & minimum length of 250mm for sizes 10” & above,
with same or higher in terms of material, grade & wall thickness as mentioned in the data
sheet. Length of pup piece shall be confirmed by manufacturer so as to avoid damage to
seats during field welding or post weld heat treatment. Pup piece thickness shall be
calculated for the class rating. Vendor shall provide for each type (considering size, grade
and thickness of the pup pieces used for all offered valves) of pup piece, test rings (500
mm long) from pup piece material for field weld procedure qualification. Valves shall be
tested along-with pup piece.
b) The pipe material, grade & thickness for pup piece shall be as per data sheet/ piping
material specification. The pipe material for pup piece shall be conforming to
specification nos. A286-000-11-42-SP-0001 (LSAW), A286-000-11-42-SP-0005 (EW) &
Technical note for pipes doc. no. 6-44-0051 as applicable.
c) The Charpy V-notch impact testing of pup piece (API 5L material) as indicated in data
sheet shall be carried out at -20°C & the energy values shall be as per specification nos.
A286-000-11-42-SP-0001 (LSAW), A286-000-11-42-SP-0005 (EW).
d) The Charpy V-notch impact testing of pup piece (low temp. carbon steel material) as
indicated in data sheet/ piping material specification shall be as per applicable codes as
specified in the technical note for pipes doc. no. 6-44-0051.

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 7 of 14
e) The pup piece shall be subjected to all the testing (Charpy, Tensile, Hardness, NDT etc.)
requirements as mentioned in QAP. Inpection frequency, acceptance criteria & reference
standards shall be as per applicable specifications/QAP.
4.18 Valve shall be provided with ball position indicator and stops of rugged construction at the
fully open and fully closed positions.
4.19 Valves shall be suitable for either buried or above ground installation as indicated in Valve
Data Sheet.
4.20 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions.
a) Stem extension material shall be equivalent to stem material or as indicated in the
data sheets for below ground valves. Stem shall be single piece construction & no
joints are permitted.
b) Valves provided with stem extension shall have water proof outer casing. Length of
stem extension shall be as indicated in Valve Data Sheet. The length indicated
corresponds to the distance between centerline of the valve opening and the top of
mounting flange for valve operating device (gear operator/power actuator as
applicable).
c) Vent and drain connections and sealant injection lines shall be terminated adjacent to
the valve operator by means of suitable piping anchored to the valve body. The pipe
used shall be ASTM A 333 Gr. 6, with Sch. 160 for sizes 0.5 to 1.5 inch. Fittings
shall be ASTM A 350 LF2 Socket welded ANSI class 6000.
d) Stem extension and stem housing design shall be such that the complete assembly
will form a rigid unit giving positive drive under all conditions with no possibility of
free movement between valve body, stem extension or its operator.
e) Outer casing of stem extension shall have ⅜”" or ½" NPT plugs at the top and
bottom, for draining and filling with oil to prevent internal corrosion. Outer casing
material shall be ASTM A 333 Gr. 6 & thickness shall be minimum Sch. 160 for 2”
& below.
4.21 Operating Devices
a) Valves shall have a gas over oil (GOO) power actuator or manual operator or
hydraulic operated as indicated in the Valve Data Sheet. Valves of sizes, DN 100
mm (4”) shall be wrench operated, valve sizes of size DN 150 mm (6”) to DN 300mm
(12”) shall be gear operated and valves of sizes above DN 300 mm (12”) shall be
hydraulic operated ( except future actuated valves of size above 12” as indicated in
valve data sheet shall be gear operated. ) unless otherwise indicated in the valve data
sheets. Each wrench-operated valve shall be supplied with wrench. Valve design shall
be such that damage due to malfunctioning of the operator or its controls will only
occur in the operator gear train or power cylinder and that damaged parts can be
replaced without the valve cover being removed.
b) The gas over oil (GOO) actuator shall be in accordance with the specification issued
for the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time
shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to
full close to full open /full open to full close under maximum differential pressure
corresponding to the valve rating. For actuated valves, the actuator’s rated torque

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 8 of 14
output shall be 1.25 times the break torque required to operate the ball valve under the
maximum differential pressure corresponding to the Valve Class Rating.
c) For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, the total
force required to operate the valve does not exceed 350N. However, failing to meet
above requirement, vendor shall offer Gear operated valves. Manufacturer shall also
indicate the number of turns of hand wheel in case of gear operators (along with their
offer) required for operating the valve from full open to full close position. The
number of turns shall not exceed 250 for valve sizes up-to 24” and 450 for valve sizes
above 24”.
All hydraulic operated valves shall be as per specification issued for purpose and as
indicated in the data sheets.
d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while

closing the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully
encased in water proof/splash proof enclosure and shall be filled with suitable grease.
4.22 The tolerance on internal diameter and out of roundness at the ends for welded ends valves
shall be as per connected pipe specification as indicated in the Valve Data Sheet.
4.23 When indicated in Material Requisition, valves shall have locking devices to lock the valve
either in full open (LO) or full close (LC) positions. Locking devices shall be permanently
attached to the valve operator and shall not interfere with operation of the valve.
4.24 All welds shall be made by welders and welding procedures qualified in accordance with the
provisions of ASME Section IX. The procedure qualification shall also include impact test and
hardness test when required as per Clause 3.4 and 3.5 of this specification and shall meet the
requirements as specified therein.
4.25 Repair by welding is not permitted for cast body and forged body valves.
4.26 No casting is permitted for stem and stem extension material of all valves. Valve stem shall be
capable of withstanding the maximum operating torque required to operate the valve against
the maximum differential pressure corresponding to applicable class rating. The combined
stress shall not exceed the maximum allowable stresses specified in ASME section VIII,
Division 1. For power actuated valves, the valve stem shall be designed for maximum output
torque of the selected power actuator (including gear box, if any) at valve stem.
4.27 Wherever specified for the parts of valve in valve datasheets, minimum thickness of stelliting
shall be 1.6 mm.
5.0 INSPECTION AND TESTS
5.1 The Manufacturer shall perform all inspection and tests as per the requirements of this
specification, quality assurance plan (QAP) and the relevant codes, prior to shipment, at his
Works. Such inspection and tests shall be, but not limited to, the following:
5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves shall be
free from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly
cleaned and free from dirt, rust and scales.
5.1.2 Dimensional check on all valves shall be carried out as per the Company approved drawings.

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 9 of 14
5.1.3 Chemical composition and mechanical properties shall be checked as per this specification
and relevant material standards, for each heat of steel used. All testing frequency shall be as
per Inspection & Test Plan/ QAP. Heat treatment chart for forging material shall be witness &
start/stop time signed by TPIA.
5.1.4 Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer.
a) Body castings of all valves shall be radiographically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B16.34. The extent of the
radiography shall be as under:
Pressure Class Rating & Size Extent of Radiography

ANSI 150 # Class for all sizes 100%
Radiography shall be performed after the final heat treatment also.
All castings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B16.34.
b) All valves, with body fabricated from plates or made by forgings, shall be ultrasonically
examined in accordance with the procedure and acceptance standard of Annexure E of
ASME B16.34.
All forgings shall be wet magnetic particle inspected 100% of the internal surfaces.
c) Bodies and bonnets made by welded assembly of segments of castings, forgings, plates
or combinations thereof shall be examined, as applicable, by methods of 5.1.4 (a) for
cast components or 5.1.4 (b) for forged components and plates.
5.1.5 Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.4 or ASME B31.8 as applicable and API 1104.
5.1.6 Welds & valve body weld joints, which in Company's opinion cannot be inspected by
radiographic methods, shall be checked by ultrasonic or magnetic particle methods and
acceptance criteria shall be as per ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6
respectively.
5.1.7 a) All finished wrought weld ends subject to welding in field shall be 100%
ultrasonically tested for lamination type defects for a distance of 50 mm from the end.
Laminations shall not be acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100% radiographically
examined and acceptance criteria shall be as per ASME B16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet
magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the
defects between 6.35 mm and 1.59 mm that are separated by a distance less than 50

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 10 of 14
times their greatest length. Rejectable defects must be removed. Weld repair of bevel
surface is not permitted.
5.1.8 All valves shall be tested in compliance with the requirements of API 6D. During pressure
testing, valves shall not have sealant lines and other cavities filled with sealant, grease or other
foreign material. The drain, vent and sealant lines shall be either included in the hydrostatic
shell test or tested independently. Test pressure shall be held for at least 30 minutes for both
Shell & Seat test. No leakage is permissible during hydrostatic testing. The body cavity self-
relieving feature meeting the requirements of clause 4.14 of this specification shall also be
checked.
In addition to above pneumatic testing shall be carried out at 95 bar (g) for 600# pressure
rating valves, using nitrogen for 5 minutes.
5.1.9 A supplementary air seat test as per API 6D (Appendix C, Para C.3.3 Type II) shall be carried
out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is
allowed. Test pressure shall be held for at least 15 minutes.
In addition to above the helium leak test shall be carried out as per API 6D. The duration &
test procedure shall be same as supplementary air seat test.
5.1.10 Valves shall be subjected to Operational Torque Test as per API 6D (Appendix C, Para C.6)
under hydraulic pressure equal to maximum differential pressure corresponding to the
applicable ANSI class rating of valve. It shall be established that the force required to operate
the valve does not exceed the requirements stated in section 4.20 (c) of this specification.
5.1.11 GOO power actuated & Hydraulic operated valves shall be tested after assembly of the valve
and actuator, at the valve Manufacturer’s works. At least five Open-Close-Open cycles
without internal pressure and five Open-Close-Open cycles with maximum differential
pressure corresponding to the valve rating shall be performed on the valve actuator assembly.
The time for Full Open to Full Close shall be recorded during testing. If required, the actuator
shall be adjusted to ensure that the opening and closing time is with in the limits stated in
Valve Data Sheet.
Hand operator provided on the actuator shall also be checked after above testing, for
satisfactory manual over-ride performance.
These tests shall be conducted on all valves. In case, the tests do not meet the requirements,
retesting/rejection of the lot shall be decided by the Company’s Inspector.
5.1.12 Subsequent to successful testing as specified in clause 5.1.10 and 5.1.11 above, one (1) valve
per size out of the total ordered quantity shall be randomly selected by the Company
Representative for cyclic testing as mentioned below:
a) The valve shall be subjected to at least 100 Open-Close-Open cycles with maximum
differential pressure corresponding to the valve rating.
b) Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.
In case this valve fails to pass these tests, the valve shall be rejected and two more valves shall
be selected randomly and subjected to testing as indicated above. If both valves pass these
tests, all valves manufactured for the order (except the valve that failed) shall be deemed
acceptable. If either of the two valves fails to pass these tests, all valves shall be rejected or
each valve shall be tested at the option of manufacturer.
Previously carried out test of similar nature shall be considered acceptable if the same has
been carried out by Manufacturer in last two years. Valves of two sizes below and two sizes

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 11 of 14
above the size of valve previously tested, and rating similar or one rating lower of valve tested
previously, shall be qualified.
5.1.13 Checks shall be carried out to demonstrate that the dissimilar metals used in the valves are
successfully insulated as per the requirement of clause 4.13 of this specification.
5.2 Company reserves the right to perform stage wise inspection and witness tests as indicated in
clause 5.1 above at Manufacturer's works prior to shipment. Manufacturer shall give
reasonable access and facilities required for inspection to the Company's Inspector. Company
reserves the right to require additional testing at any time to confirm or further investigate a
suspected fault. The cost incurred shall be to Manufacturer’s account.
In no case shall any action of Company or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves.
Inspection and tests performed/witnessed by the Company’s Inspector shall in no way relieve
the Manufacturer’s obligation to perform the required inspection and tests.
6.0 TEST CERTIFICATES
Manufacturer shall submit the following certificates:

a) Mill test certificates relevant to the chemical analysis and mechanical properties of the
materials used for the valve construction as per the relevant standards.
b) Test certificates of hydrostatic and pneumatic tests, helium test complete with records
of timing and pressure of each test.
c) Test reports of radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 5.1.10, 5.1.11 and 5.1.12
of this specification.
e) All other test reports and certificates as required by API 6D and this specification.
The certificates shall be considered valid only when signed by Company's Inspector. Only
those valves which have been certified by Company's Inspector shall be dispatched from
Manufacturer's works. TPIA shall issue 3.2 certificates as per BS EN 10204.
7.0 PAINTING, MARKING AND SHIPMENT
7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot
blasting to SP-6 in accordance with "Steel Structures Painting Council - Visual Standard
SSPC-VIS-1"/ Sa 2 ½ in accordance with "Swedish standard - SIS-055900" as per
specification no. 6-44-0004.
All buried valves, when indicated in valve data sheet, the external surfaces of buried portion of
the valve shall be provided with high build epoxy coating with a min. thickness 500 microns
DFT (dry film thickness) or PU coating of thickness DFT 1.5mm (min.).
All above ground valves shall be painted as per specifications no. 6-44-0004 suitable for
“Geographical corrosive” environment.
7.2 All valves shall be marked as per API 6D. The units of marking shall be metric except
nominal diameter, which shall be in inches.
7.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by Moly coat type grease or
(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 12 of 14
other suitable material. All valves shall be provided with suitable protectors for flange faces,
securely attached to the valves. Bevel ends shall be protected with metallic or high impact
plastic bevel protectors.
7.4 All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
7.5 Packaging and shipping instructions shall be as per API 6D.
7.6 On packages, following shall be marked legibly with suitable marking ink:
a) Order Number
b) Manufacturer's Name
c) Valve size and rating
d) Tag Number
e) Serial Number
8.0 SPARES AND ACCESSORIES
8.1 Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning and supply of such spares shall be included in the price
quoted by Manufacturer.
8.2 Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves and price for such spares shall be quoted
separately.
9.0 DOCUMENTATION
Documentation to be submitted by Manufacturer to Company is summarized below. Number
of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.
9.1 At the time of bidding, Manufacturer shall submit the following documents:
a) General arrangement/ Sectional drawing & blow-up drawing of seat assembly shall be
submitted. Number of turns for Gear Operated valves shall be indicated in the GA or
shall be furnished separately.
b) Reference list of similar ball valves manufactured and supplied in last ten years
indicating all relevant details including project, year, client, location, size, rating,
service etc.
c) Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque.
e) Copy of valid API 6D Certificate.
f) In case of soft seated valves, copy of Fire Safe test certificate of qualifying valve as
per API 6FA carried out in last 10 years shall be furnished.
g) Details of support foot including dimensions and distance from valve centerline to
bottom of support foot.
h) List of recommended spares required during start-up and commissioning & 2 years of
normal operation and maintenance.

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 13 of 14
9.2 After placement of order, the Manufacturer shall submit the following drawings, documents
and specifications for Company's approval:
a) Detailed sectional drawings showing all parts with reference numbers and material
specifications.
b) Assembly drawings with overall dimensions and features. Drawing shall also indicate
the number of turns of hand wheel (in case of gear operators) required for operating
the valve from full open to full close position and the painting scheme. Complete
dimensional details of support foot (where applicable) shall be indicated in these
drawings.
Manufacture of valves shall commence only after approval of the above documents. Once the
approval has been given by Company, any changes in design, material and method of
manufacture shall be notified to Company whose approval in writing of all changes shall be
obtained before the valve is manufactured.
9.3 Within 30 days from the approval date, Manufacturer shall submit to Company the approved
drawings, documents and specifications as listed in clause 9.2 above.
9.4 Prior to shipment, Manufacturer shall submit to Company following:
a) Test certificates as per clause 6.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions including a

list of recommended spares for the valves.
9.5 All documents shall be in English language only.

(ONSHORE) A286-000-11-42-SP-0014 Rev. 0
Page 14 of 14
FIGURE-4.9
ADDITIONAL NOTES:
1. FOR ABOVE GROUND INSTALLATION: ALL DRAIN & VENT CONNECTION SHALL BE EQUIPPED WITH ONE NO. (1) BALL
VALVE, ONE NO. (1) NEEDLE VALVE, ONE NO. (1) DEPRESSURIZING PLUG AT THE TERMINATING END. NO THREADED
CONNECTIONS ARE PERMITTED. ALL PIPES & FITTINGS SHALL BE SCH. 160 & 6000# RESPECTIVELY FOR ALL DRAIN, VENT &
SEALENT CONNECTIONS.
2. FOR UNDER GROUND INSTALLATION: ALL DRAIN & VENT CONNECTION SHALL BE EQUIPPED WITH ONE NO. (1) BALL
VALVE AT BODY TAP, ONE NO. (1) BALL VALVE, ONE NO. (1) NEEDLE VALVE, ONE NO. (1) DEPRESSURIZING PLUG AT THE
TERMINATING END. NO THREADED CONNECTIONS ARE PERMITTED. ALL PIPES & FITTINGS SHALL BE SCH. 160 & 6000#
RESPECTIVELY FOR ALL DRAIN, VENT & SEALENT CONNECTIONS.

SPECIFICATION FOR PIG
SIGNALLERS (NON INTRUSIVE) A286-000-11-42-SP-0033 Rev 0
Page 1 of 7

SPECIFICATION FOR PIG SIGNALER

(NON-INTRUSIVE)
0 08.09.12 ISSUED FOR BIDS SG SRG MSG
A 22.08.12 ISSUED FOR CLIENTS COMMENTS SG SRG MSG

Date Purpose
No by by by

Page 2 of 7
CONTENTS
1.0 SCOPE ........................................................................................................................................ 3
2.0 REFERENCE DOCUMENTS .................................................................................................... 3
3.0 MATERIAL ................................................................................................................................ 3
4.0 DESIGN AND CONSTRUCTION REQUIREMENT ............................................................... 3
5.0 INSPECTION AND TESTS ....................................................................................................... 5
6.0 TEST CERTIFICATES ............................................................................................................... 6
7.0 PAINTING, MARKING AND SHIPMENT .............................................................................. 6
8.0 SPARES AND ACCESSORIES ................................................................................................. 6
9.0 DOCUMENTATION .................................................................................................................. 7

Page 3 of 7
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture, testing and
supply of clamp on type, non-intrusive and passive acoustic based pig signallers for pipeline
systems.
Reference has been made in this specification to the latest edition (edition enforce at the time
of issue of enquiry) of the following codes, standards and specifications:
a) ASTM A 694 - Standard Specification for Carbon and Alloy Steel forgings
for Pipe Flanges, Fittings, Valves and Parts for High Pressure
Transmission
b) BS EN 10204 - Metallic Materials – Types of Inspection Documents
c) IEC 60079 - Electrical Apparatus for Explosive Gas Atmospheres
e) IEC 60364 - Earthing Standard
f) IEC 60529 - Degrees of Protection Provided by Enclosures (IP Code)
g) API 1104 - Welding of Pipelines and Related Facilities
In case of conflict between the requirements of this specification and the requirements of
above referred codes, standards and specifications, the requirements of this specification shall
govern.
3.0 MATERIAL
3.1 Sensor Housing and Termination Junction Box shall be constructed from AISI 316L Stainless
Steel. The material of the brackets shall be as per the Piping Class.
4.0 DESIGN AND CONSTRUCTION REQUIREMENT
The pig detector should be able to monitor, reliably, when the pig is passing the point of
installation. This shall be achieved by using a passive acoustic technology which shall be non-
intrusive.
Signallers shall be capable of indicating the passage of all types of pigging devices include
intelligent pigs and spheres.
There should be no needs for inserts in the pigs and the system should be capable of detecting
all types of pigs or plugs.
It should be possible to provide the light indication and reset switch at a distance of minimum
5 meters from the sensor.
The total weight of the assembly should not exceed 10.0 kg.
4.1 SENSOR
The sensor should be an intelligent non-invasive, passive ultrasonic type powered from a 24
VDC + 10% power supply.

Page 4 of 7
It should have the following characteristics as a minimum.
The sensor element should be a Piezo electrical crystal.

The sensor should have minimum repeatability of 1%.
It should not contain any moving parts and be top side mountable.
It should be bidirectional having two-way communication with real time measurement and
should be able to detect the pig in oil, water, gas or multiphase fluids having flow velocity
of 0.03 m/s or greater.
The sensor enclosure shall be certified for EExd TIB T5 minimum.
The sensor shall be able to work for pipe surface temperature from -20 to +65 0C; the
ingress protection shall be IP-65 minimum.
The sensor should be able to provide the following output signals.
- Potential Free Contact.
- Modbus RTU RS485/ Ethernet.
The senor should have Digital Signal Processing (DSP) capability.
The software should be easily upgradeable.
It should be able to store up to 60 days of measurement data.
It should have self testing capabilities.
The same sensor should be able to perform particle detection, pig detection, spectrum
analysis using associated software; the requirement of the same shall be indicated in the
data sheet.
4.2 TERMINATION JUNCTION BOX
Termination junction boxes shall be provided for connecting the sensor cables to the power
and signal cables, the light indication and rest switch.
The termination junction box shall be constructed of SS316 material and shall be certified as
EExed IIB, IP65 minimum.
Four Nos. ½” NPTF cable gland entries are to be provided; all the entries shall be blinded with
suitable EExed/ EExd plugs.
4.3 LOCAL INDICATION
Local indication light shall be LED based, RED in Color, EExe IIB T5 1P65 certified. It
should be possible to locate indication light at a distance of at least 5 meter away from the
sensor.
4.4 LOCAL RESET SWITCH
Local reset switch shall be PUSH BUTTON type, Black Color, EExe and EExd MO IP65
certified and installed on top of termination junction box. It should be possible to locate the
local reset switch at a distance of a least 5 meter away from the sensor.
4.5 SKID AND BRACKETS
Manufacturer shall provide standard installation drawing for mounting of sensor on pipe,
which should indicate the welding details of the support brackets to the pipe as a minimum.
The sensor will be bolted to the support brackets.
Butt Welded Joints or Circumferential joints shall be 100% radio graphically inspected.

Page 5 of 7
Company reserves the right to require ultrasonic testing where radiography may produce
questionable result.
In the event that welds performed on any performed on any forging cannot be 100 percent
radio graphed by gamma and X-ray, then ultrasonic and wet fluorescent magnetic particle
testing may be used with the approval of Company.
Welding procedure specifications and procedure qualification records shall be furnished to the
Company for approval prior to fabrication.
All Welding procedure specifications and procedure specifications, procedure qualification

records, welder qualification test, design and preparation of joints, inspection and testing,
standards of acceptability, repairs and radiography shall be as per approved procedure.
5.1 The Manufacturer shall perform all inspections and tests as per the requirements of this
specification and the relevant codes, standards and specifications, prior to shipment at his
Works. Such inspections and tests shall be, but not limited to, the following:
5.1.1 All pig signallers shall be visually inspected. The internal and external surfaces shall be free
from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly
5.1.2 Testing and assembly procedure shall be detailed by Manufacturer; approved by the Company
and implemented during the work. Welding Inspection and testing shall be performed before
any coating or painting is applied.
5.1.3 Each Weld shall be examined by 100 percent radiography (RT). In addition, carbon steel
welds shall receive 100 percent magnetic particle examination (MT) and stainless steel welds
shall receive 100 percent liquid penetrant examination (PT).
Radiography Test (RT) shall be in accordance with ASME BPV Code Section V, Articles 2
and 22, with acceptance criteria in accordance with ASMEBPV Code Section VIII, Division
1, Part UW-51.
Magnetic Particle Test (MT) shall be in accordance with ASME BPV Code Section V,
Articles 7 and 25, with acceptance criteria in accordance with ASMEBPV Code Section VIII,
Appendix 6.
Liquid Penetrant Examination (PT) shall be in accordance with ASME BPV Code Section V,
Articles 6 and 24, with acceptance criteria in accordance with ASMEBPV Code Section VIII,
Appendix 8.
5.1.4 Visual examination methods shall be in accordance with ASME BPV Code section V, Article
9.
5.1.5 The Contractor shall adequately demonstrate that all aspects of the pig detector operate in
simple full proof manner.
5.1.6 The self test shall be carried out after installation to verify the functionality of the sensor.

Page 6 of 7
Manufacturer shall submit the following test certificates:
6.1.1 3.2 Certificate as per EN 10204.
6.2 Test certificates for material compliance as per relevant material standards.
6.3 Test reports of ultrasonic/magnetic particle inspection.
6.4 Instrument of Pig Signaller shall be supplied with CCOE certification:
For all intrinsically safe/ explosion proof/flameproof equipments/ instruments/systems or

equipments with any other type of protection allowable as per this package which are
manufactured abroad and certified by any statutory authority like BASEEFA, FM, UL,
PTB, LCIE etc. should also have the approval of Petroleum And Explosives Safety
Organisation (PESO)/ Chief Controller of Explosives (CCE), Nagpur.
For all flame proof equipments manufactured locally (indigenously), the testing shall be
carried out by any of the approved test house like CMRI/ERTL etc. The equipment shall
in addition bear the valid approval from Petroleum And Explosives Safety Organisation
(PESO)/ Chief Controller of Explosives, Nagpur and a valid BIS license.
7.1 After all inspection and tests required have been carried out; the exterior surface of the pig
signaller shall be thoroughly cleaned, free from rust and grease and applied with sufficient
coats of corrosion resistant paint. Manufacturer shall indicate the type and corrosion resistant
paint used in the drawings submitted for approval.
7.2 A corrosion resistant metal tag shall be permanently attached with each unit, with the
following marking:
i) Manufacturer’s name.
ii) Suitable for installation in ______mm dia. pipeline
iii) Tag No.
7.3 Each unit shall be suitably protected to avoid any damage during transit. Care shall be
exercised during packing to prevent any damage to the welding ends. All machined surfaces
subject to corrosion shall be well protected by a coat of grease or other suitable materials.
8.1 Manufacturer shall furnish list of recommended spares and accessories for pig signallers
required during start-up and commissioning and supply of such spares shall be included in the
price quoted by Manufacturer.
8.2 Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of pig signallers and price for such spares shall be
quoted separately.
8.3 Manufacturer shall provide special tools required for operation and maintenance as a part of
supply, this includes but not limited to

Page 7 of 7
Any type of communicator/ cables/ connectors for configurations;

Any Software (licensed copy) required for configuration or change of parameters, software
shall be “Windows” based.
Any Special tools required for maintenance like special type of Alien Key etc.
9.0 DOCUMENTATION
Documentation (Hard copies / soft copies etc.) to be submitted by Manufacturer to Company

is summarized below.
a) General arrangement drawings with overall dimensions and cross-sectional drawings.
b) Reference list of similar supplies of pig signaller shall be furnished including Project,
Year of supply, Client, Size and Service for the last five years.
and specifications for Company’s information & review.
a) Sectional arrangement drawings showing all parts with reference numbers and
material specification including mounting details of pig signallers on the pipeline.
b) Assembly drawing with overall dimensions
c) Cable connection details and cable specification.
9.3 Prior to shipment, Manufacturer shall submit following:
a) Test Certificates as per clause 6.0 of this specification.
b) Manual for installation, erection instructions, maintenance and operation instructions.
9.4 Final drawings/ documents as indicated in clause no. 9.2 above shall be submitted in soft
format also.
9.5 All documents shall be in English language.

INSULATING GASKET A286-000-11-42-SP-0034 Rev. 0
ASSEMBLY
Page 1 of 6

SPECIFICATION FOR
INSULATING FLANGE ASSEMBLY

Date Purpose
No by by by
ASSEMBLY
Page 2 of 6
TABLE OF CONTENTS
1.0 SCOPE
2.0 DESIGN AND CONSTRUCTION
3.0 MATERIALS
4.0 INSPECTION AND TESTING
6.0 MARKING AND SHIPMENT
7.0 DOCUMENTATION
ASSEMBLY
Page 3 of 6
1.0 SCOPE
This specification covers the design, fabrication, inspection and supply of

insulating gasket kit to be installed in pipelines handling hydro carbon for absolute
flange sealing and electrical isolation of the section of piping. This specification
does not cover monolithic/mono-block type insulating joints.
2.1 All the items used in the construction of insulating gasket, their dimensions,
tolerances, chemical composition, physical properties, heat treatment, if any,
testing etc. shall conform to the Codes and Standards specified for the item.
2.2 Manufacturer shall guarantee that Insulating Gasket shall with stand test pressure
equal to 1.5 times design pressure of Pipeline.
2.3 No parts of the insulating gasket assembly shall be painted.
3.0 MATERIALS
3.1 GASKETS
3.1.1 Type of gasket to be used and manufacturing standard for the gasket shall be as
indicated in the Data Sheet. The process of manufacture dimensions and
tolerances not specified in the applicable manufacturing standard shall be as per
Manufacturer’s standard.
3.1.2 Full-face gaskets, when specified, shall have bolt holes punched out.
3.1.3 Asbestos shall not used.
3.2 INSULATING MATERIALS
3.2.1 Materials used in the fabrication of insulating components such as insulating

gaskets, sleeves, washers etc. shall be Glass Reinforced Epoxy (GRE) NEMA
Grade G-10 Materials with following electrical properties:
Dielectric Strength (min) = 550 VPM

Electrical Resistance = 25 Mega Ohm
(When tested with 500-1000V DC megger).
3.2.2 The Non Metallic Gasket as per ASME B 16.21 shall match flanges to ASME B
16.5 upto 24” (except size 22”). The insulating gasket and washers shall have
adequate compressive strength to permit proper tightening of flange bolts for leak
proof joint. However, minimum compressive strength of GRE insulating material
shall be 65000 psi.
3.2.3 The insulating material shall have maximum water absorption of 0.05%.
3.2.4 The insulating material shall be suitable for pressure and temperature indicated in
Data Sheet under connecting pipe details and shall be resistant to the fluid to be
handled through the pipeline.
3.2.5 I.D. and O.D. of insulating washers shall be designed to fit over insulating sleeves
and within spot faces on flanges.
ASSEMBLY
Page 4 of 6
3.2.6 Insulating Sleeves shall be made of either Mylar tubing or Glass Reinforced epoxy
according to NEMA standard.
3.3 BOLTING
3.3.1 The material for the bolts/studs and nuts shall be as specified in Data Sheet.
3.3.2 All bolting shall be as per ASME B 18.2.1 for bolts/studs and ASME B 18.2.2 for
nuts.
3.3.3 Threads shall be unified (UNC for 1" dia. and 8UN for > 1" dia.) as per ANSI
B.1.1 with class 2A fit for bolts/studs and class 2B for nuts.
3.3.4 Studs/bolts shall be threaded full length with two heavy hexagonal nuts. Length
tolerance shall be in accordance with the requirement of table F2 of Annexure F of
ANSI B16.5.
3.3.5 The nuts shall be double chamfered, semi finished, heavy hexagonal type and
shall be made by the hot forged process and stamped as per respective material
specification.
3.3.6 Bolts/studs and nuts of material of construction as B7 and 2H respectively shall be

100% hardness tested as per supplementary requirement S3 of ASTM A193.
3.3.7 Thickness and material for steel washers shall be as indicated in Data Sheets.
4.1 The manufacturer shall perform all inspections and tests as per the requirements
of this specification and the applicable codes at his works prior to shipment. Such
inspections and tests shall be, but not be limited to the following:
4.1.1 All the insulating gasket assemblies shall be visually inspected.
4.1.2 Insulating flange assembly shall be hydrostatically tested to a pressure equal to

1.5 times design Pressure in following manner;
5 minutes at a hydrotest pressure.
Reduce to Zero.
Repeat the above procedure twice
4.1.3 Insulating flange assembly shall be tested with air at 5 kg/cm2 for 10 minutes. The
tightness shall be checked by immersion or with a frothing agent. No leakage shall
be accepted.
4.1.2 Dimensional checks shall be carried out as per Purchaser Approved Drawings.
4.1.3 Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of material used.
4.1.5 Each insulating gasket shall be tested for dielectric integrity at 5000 V A.C., 50 Hz
for one minute and the leakage current before and after shall be equal. Testing
time, voltage and leakage shall be recorded and certified. The test shall be carried
out in dry conditions.
ASSEMBLY
Page 5 of 6
The insulation resistance of each insulating gasket assembly shall be at least 25

mega ohms when checked with 500V - 1000V D.C. This test shall be carried out in
dry conditions.
Each Insulating Gasket Assembly shall be Dielectric Tested before and after
hydrostatic Test.
4.2 Purchaser reserves the right to perform stage wise inspection and witness tests as
indicated above at Manufacturer’s Works prior to shipment. Manufacturer shall
give reasonable notice of time and shall provide, without charge, reasonable
access and facilities required for inspection by the Inspector.
Inspections and tests performed/witnessed by the Inspector shall in no way relieve

the Manufacturer of his obligation to perform the required inspection and tests.
5.1 Manufacturer shall submit the following test certificates:
a. Test certificates related to the chemical analysis and mechanical tests for the
materials used for construction as per this specification and relevant
standards and this specification.
b. Certificate stating that for each insulating gasket assembly shall be capable of
withstanding hydrostatic test pressure of 1.5 times of Design pressure of
pipeline without any leakage.
c. Test certificates for electrical tests.
d. Manufacturer’s test certificates for material.
6.0 MARKING AND SHIPMENT
6.1 All the items shall be stamped in accordance with the requirements of applicable
Codes and Standards.
6.2 All the items shall be dry, clean and free from moisture, dirt and loose foreign
materials of any kind.
6.3 All the items shall be protected from rust, corrosive and mechanical damage during
transportation, shipment and storage etc.
6.4 Rust preventive on machined surfaces to be welded shall be easily removable with
a petroleum solvent and the same shall not be harmful to welding.
7.0 DOCUMENTATION
7.1 At the time of bidding, the manufacturer shall furnish following information:
a. Reference list of supply of insulating gasket for similar application for the last
five (05) years indicating Name and address of Client, year of supply, fluid
handled, material of construction etc.
b. List of deviations to this specification, if any.
ASSEMBLY
Page 6 of 6
c. Catalogues, cross sectional drawings of the proposed insulating gasket

assembly including design features and material of construction, QA/QC
procedures etc.
7.2 After placement of order, the manufacturer shall submit, but not limited to, the
following documents for Purchaser’s approval:
a. Fabrication drawings indicating material of construction.

b. Inspection and testing procedures.
Once the documents are approved by the Purchaser; any change in design,
material or method of manufacturer shall be implemented only after approval of
Purchaser in writing.
7.3 Prior to shipment, the manufacturer shall submit test certificates as listed in clause
5.0 of this specification.
Document No.
SPECIFICATION FOR GAS
OVER OIL ACTUATORS A286-000-11-42-SP-0079, Rev. B
Page 1 of 14

SPECIFICATION FOR GAS OVER OIL ACTUATORS
B 09.08.12 ISSUED AS JOB SPECIFICATION

RB NR MSG
A 12.06.12 ISSUED FOR COMMENTS

SG NR MSG
Rev. No Date Purpose Prepared by Checked by Approved by
Format No. EIL 1641-1924 Rev. 1 GOO Actuator Job Specification_rev B Copyright EIL – All rights reserved
Document No.
Page 2 of 14
CONTENTS
1.0 SCOPE ................................................................................................................... 3
2.0 REFERENCE DOCUMENTS .................................................................................. 3
3.0 ACTUATOR SIZING ............................................................................................... 4
4.0 MATERIALS ........................................................................................................... 5
5.0 DESIGN AND CONSTRUCTION ............................................................................ 5
6.0 INSPECTION AND TESTS ..................................................................................... 9
7.0 SHIPPING ............................................................................................................. 10
8.0 TEST CERTIFICATES/REPORTS ........................................................................ 11
9.0 PAINTING AND MARKING .................................................................................. 11
10.0 SPARES AND SPECIAL TOOLS ......................................................................... 12
11.0 DOCUMENTATION .............................................................................................. 12
Document No.
Page 3 of 14
1.0 SCOPE
1.1 This specification, together with applicable data sheets covers, the minimum
requirements for design, manufacture, inspection and testing of quarter turn gas
over oil (GOO) actuators complete with accessories suitable for operation of ball
valves in pipeline/piping systems handling hydrocarbons in gaseous phase.
.
1.2 This specification indicates the minimum supply requirements and does not relieve
the Vendor from his responsibilities concerning the design and the safe operation
of the supplied equipment.
1.3 The valve manufacturer shall also be responsible for proper operation of the
actuator that shall develop a torque or a thrust sufficient to conveniently open and
close the valve always with in the limits established by the resistance of the
mechanical elements of the valve itself.
1.4 Valve and actuator shall be supplied as a single assembly complete in all respect
and ready for installation at site.
This specification shall be read in conjunction with Company data sheets and
specifications for pipeline ball valves.
Reference has been made in this specification to the latest edition of the following
Codes, Standards and Specifications:
Codes and Standards
a) ASME B 31.3 - Chemical Plant and Petroleum Refinery Piping
b) ASME B31.8 - Gas Transmission & Distribution Piping

Systems.
c) ASME B 16.5 - Steel Pipe Flanges and Flanged Fittings
d) ASME B16.47 - Large dia Steel Flanges: NPS 26 through NPS

60
e) MSS SP 44 - Steel pipeline flanges
f) ASME Sec VIII - Boiler and Pressure Vessels Code
g) ANSI B 1.20.1 - Pipe Threads, General Purpose
h) NEC - National Electric Code
i) IEC - International Electro Technical Commission &

Sec IX
j) MSS-SP-101 - Part-Turn Valve Actuator Attachment - Flange

and Driving Component Dimensions and
Performance Characteristics
Document No.
Page 4 of 14
k) SSPC-VIS-1 - Steel Structures Painting Council Visual

Standard
l) IEC-60079 - Electrical apparatus for explosive gas

atmosphere
m) IEC-60529 - Degree of protection provided by enclosure
Purchaser Specification
6-71-0014 : Standard Specification for Ball Valves (Onshore)
In case of conflict between the requirements of this specification and Codes,

standards and specifications referred above, the requirements of this specification
shall govern.
3.0 ACTUATOR SIZING
3.1 For sizing the actuator, Valve manufacturer shall furnish to the actuator
manufacturer the following information:
a) The maximum break-away torque or thrust required at the valve stem with
manual/remote operation to open and close a valve at the shut off pressure
in the line. The actuator shall be sized at 25 kg/cm2g gas pressure and
meeting the safety factor of 1.25 as required by the valve operation at the
shut-off pressure in the line.
b) The temperature correction factor.
c) The pressure correction factor.
d) As a result of points (a) to (c) the minimum required torque or thrust output of
the actuator.
e) Maximum allowable torque or thrust output of the actuator depending on the

type and size of valve.
3.2 The maximum time required to open and close a ball valve shall be as indicated in
the data sheet.
3.3 Actuator manufacturer shall provide the complete model number decoding for
actuators, limit switches and solenoid valves.
3.4 Complete details of Gas & Oil (Hydraulic) circuit with complete sequencing of port
from open to close and close to open position shall be furnished in the offer for
review.
3.5 Manufacturer shall furnish the detailed calculation for actuator sizing after
placement of order. The calculation so furnished by manufacturer shall satisfy the
sizing criteria as per above clauses. Manufacturer shall agree to upgrade the
actuators offered to meet the sizing criteria without any price and schedule impact.
Document No.
Page 5 of 14
4.0 MATERIALS
Actuators shall be supplied with SS 316 stainless steel trim. Materials of all parts
and seals shall be compatible with the operating hydraulic fluid (Oil). All materials
shall be suitable for the ambient conditions and operating conditions as indicated in
the Actuator Data Sheets.
5.1 Gas over Oil (GOO) actuator shall be of rotary vane type mechanism or double
acting scotch yoke type mechanism with pistons and shall maintain the selected
valve position fully open or closed with pressure equalized. If there is no gas
pressure available to actuators it shall be possible to actuate the gas over oil
actuators by means of hydraulic oil/gas or other similar source. The actuator
manufacturer shall furnish the capacity & set pressure of gas/oil tanks for at least
two strokes (One open & one close).
5.2 The gas to be used for actuation purpose shall be sourced from main pipeline.
Vendor shall indicate the minimum pressures required for gas pressure. Actuators
shall be suitable for gas operating conditions & ambient temperature as specified in
data sheet(s). Presence of methanol in the gas shall not affect the service of
actuators.
5.3 All materials in contact with natural gas shall be suitable for gas composition
attached with this specification.
5.4 Actuator body shall be designed to ASME B31.3 and all body joints shall be in
accordance with ASME Section VIII, Division 1.
5.5 Actuator shall be suitable for direct mounting on the ball valves without changing
the standard top works of the valve and shall have the capability to be mounted or
removed from the valve when the valve is in service. Insulating gasket shall be
provided on valve body at stem location & actuator connection.
5.6 All pressure and load carrying components in the actuator shall be designed to
withstand the maximum output thrust without affecting valve performance.
5.7 Actuator shall be sized considering the break-away thrust corresponding to

maximum differential pressure of valve ASME/ANSI Rating required at the valve
stem to open and close the valve. A factor of safety of 1.25 shall be considered in
the actuator design. Due correction factor shall be applied for the temperature and
pressure rating.
5.8 Actuator maximum thrust shall be limited such that the allowable stress values of
valve stem is not exceeded during valve operation.
5.9 Actuator / valve interface shall meet the applicable requirements of MSS-SP-101.
To assure geometrically accurate valve/actuator alignment, a centering ring as
required may be provided.
5.10 Actuator shall be capable of opening or closing the valves within the operating time
indicated in the Actuator Data Sheet(s) and as per clause 4.20 of specification for
Document No.
Page 6 of 14
pipeline ball valve A286-000-11-42-SP-0014. Provision shall be made for slower

actuation during maintenance and field testing activities.
5.11 Actuator shall be provided with valve position switch/indicator which shall clearly
show whether the valve in open, close or in partially open position.
5.12 Mechanical stops shall be provided to limit the actuator travel independently from
any valve stops.
5.13 Threading connection shall be NPT as per ANSI B 1.20.1 and flange connection
shall be as per ASME B 16.5 & MSS SP 44 (as applicable). The tubing, fitting and
valves shall be SS 316 stainless steel. All the fittings should be of dielectric type.
All tubing shall be properly supported and shielded from damage by a suitable
protective cover.
5.14 Each actuator shall be provided with a manual hydraulic module incorporating a
positive displacement piston pump, directional control valve etc. In addition, by-
pass for high speed operation shall also be provided. This manual hydraulic pump
module shall be mounted as an integral component of actuator.
5.15 Positive displacement hand pump to be provided as a part of the manual hydraulic
pump module shall eliminate cavitations or sucking air. It shall be possible to stroke
the hand-pump at any speed without drawing a vacuum into the pumping chamber.
The hand pump shall be provided with an individual suction filter, block valves,
pressure gauge, relief valve and check valve.
5.16 Hydraulic fluid used shall be oil based and shall have a cleanliness level of NAS
1638, Class 6. The actuator shall be supplied filled with hydraulic fluid approved by
Purchaser.
5.17 Actuator and its accessories shall be weather proof protected to IP-65 as per IEC-
600529.
5.18 All compartments and housing containing electrical devices such as switches, etc.
shall be intrinsic safe suitable for Zone- 2, group IIA/IIB, Temp. Class T3 as per
IEC/IS.
All electrical / electronic components of the Gas Over Oil Actuator, to be
intrinsically certified by the statutory authorities suitable for hazardous area
specified. The requirement of the statutory approvals for usage of equipment/
Instruments/ Systems in the electrically hazardous areas shall be as follows:
A copy of approval for items such as limit switches, Solenoid valves, electro-
pneumatic converters, smart positioned, whenever specified from local statutory
authority, as applicable, such as Petroleum & Explosive Safety Organisation
(PESO) / Chief Controller of Explosives, Nagpur (CCOE) or Director General of
Mines Safety (DGMS) in India, Along with:
i. Test certificate from recognized test house like CIMFR / ERTL etc. for
flameproof enclosure and / or intrinsic safety , as specified in the data sheet,
as per relevant Indian Standard for all Indian manufactured equipments.
ii. Certicate of conformity from agencies like LCIE, Baseefa, PTB, CSA, UL etc.
for compliance to ATEX directives or equivalent recognized standards for all
equipments manufactured outside India.
Document No.
Page 7 of 14
5.19 Provision shall be made to prevent accidental pressure build up in the actuator.
5.20 The construction of the actuator and its controls shall be such that proper manual
operation and maintenance can be carried out by skilled personnel without the risk
of being injured e.g. by moving parts.
5.21 Bearings shall be factory packed with grease and shall not require additional
lubrication for the life of the actuator.
5.22 Unless specified otherwise in the data sheet, the actuator shall be equipped with
limit valves which immediately shut off the gas supply to actuator when the valve
reaches one of its end positions.
5.23 Actuator shall be provided with pressure gauges for pneumatic and hydraulic
systems. The pressure gauges for the hydraulic system shall be in circuit with the
pressure relief system. The Pressure gauges shall be liquid filled type with dial size
of 150 mm and case material of SS304.
5.25 A high pressure dehydrating filter cartridge shall be provided to remove

condensate, moisture, foreign particles and any corrosive contaminants from
pipeline gas.
5.26 The sound level of the gas escaping into the atmosphere when the actuator is in
operation shall not exceed 85 dBA, measured at a distance of 10 meters.
5.27 The actuator shall be operated by either of the following two methods:
a) For the remote control, the actuator shall have a solenoid valve, limit
switches, relays, etc. and shall be suitable for remote and local operation
as per description in the attached Actuator Data Sheet(s). Electrical signal
supplied is a momentary type with 1 sec duration signal. Actuator shall
have a self retaining system of the above signal in its control circuit. The
Solenoid valve (SOV) shall be 24 VDC with intrinsic safe type. The body of
SOV shall be SS and solenoid coil continuously rated for specified voltage
with class F rating.
b) For the local-control the actuator shall be suitable for local operation with
line gas over oil cylinders or through nitrogen bottles. The devices and
accessories, which do not require the electricity for their operation, shall
be provided in the actuators as per this specification. The actuator shall
have a hand pump in conjunction with the oil circuit to achieve local
control with hydraulic shock functionality
5.28 Actuators shall be provided with limit switches for open and close positions. Limit
switch shall be of proximity type with NAMUR design.
5.29 The limit switches shall be wired in the actuator control circuit by the vendor so as
to cut off power to the actuator once the end positions of the valve are reached.
This is required to de-energize the solenoid valves in the steady state condition
and failure of electrical power will not affect the valve position.
5.30 The stroke of the Actuator shall be easily adjustable in steps of maximum 0.5° for
Ball valves.
Document No.
Page 8 of 14
5.31 Speed control nozzles for adjusting the valve speed over a wide range shall be
provided.
5.32 If remote control is required, a local/remote switch of flame proof type shall be
installed to prevent remote control during maintenance work. This switch shall be
provided with a hole 12mm in diameter for locking with pad lock in either position.
This local/remote switch shall be wired upto the junction box as per circuit diagram.
5.33 All control accessories, pneumatic and hydraulic, shall be mounted in an enclosure
and shall be fully wired and tube. The enclosure shall be weatherproof as per IP
65.
5.34 All bleed and vent connections wherever required shall be piped outside the
actuator cabinet so as to prevent gas pocketing inside the actuator cabinet. The
actuator will be of an automatic self purging design such that any gas pocket in the
actuator will be eliminated.
5.35 Vendor shall be responsible for integrating the potential free NO or NC contacts of
Remote Telemetry Unit (RTU's) for open and close command in interlock circuit.
These commands will be of momentary type with 1 sec. duration.
5.36 All mounting accessories needed for installing the actuator, tanks etc. are in
manufacturer's scope of supply.
5.37 The interconnecting cabling, interconnecting pipe work between the actuator and
the valve, adapters, tubing, cable glands, junction box are in manufacturer's scope
of supply.
5.38 The actuator shall be supplied totally self-contained, wired, tube and mounted on
ball valve. In case of a separate control box, wiring and tubing between control box
and actuator is in the vendor's scope. 3/4” tubing including all connectors between
the actuator and control box and interconnecting piping work upstream &
downstream of the valve and the control box shall be provided. Owner shall
provide 20 mm (3/4") SW tapping on process main line for line gas tapping.
5.39 Threading connections shall be NPT as per ANSI B 1.20.1 and flange connection
as per ANSI B 16.5/ANSI B 16.47-A Series. The tubing, fittings and valves shall be
stainless steel with Swage Lock fittings & Sandvik tubing.
5.40 All mounting accessories needed for installing the actuator and its accessories are
in manufacturer's scope of supply.
5.41 The interconnecting cabling, interconnecting pipe work between the actuator and
the manual hydraulic module, adapters, tubing, cable glands, junction box as
required are in manufacturer's scope of supply.
5.42 The Instruments junction boxes for flame proof instruments shall be providedwith
flame proof junction boxes with weather proof protection of IP-65. Also for
intrinsically safe instruments weather proof to IP-65 junction boxes to be provided.
Document No.
Page 9 of 14
The actuator Manufacturer shall perform all inspection and tests as per the
requirements of this specification and the relevant codes at his Works, such
inspection and tests shall be, but not limited to, the following:
.
6.1 Tests at the Actuator Manufacturer's Shop:
a) Electrical and mechanical operating tests.
b) Seal test of hydraulic circuits.
c) Check of required functions.
d) Check of operating time control.
e) Check of limiting device operation.
f) Check of the actuator torque or thrust.
g) Entire functional test with actual condition by operation of solenoid valves,

Limit switches, Differential pressure switch, L/R selector switch and TLD
shall be carried out.
6.2 Tests at the Valve Manufacturer's Shop
a) Test and check covered by point 6.1 after assembly with valve.
b) No load test (DP=0) or load (DP max) Operations with the minimum
required feeding pressure (10 kg/cm2g).
c) Check of the limiting device operation.
d) Various tests on the valve according to provisions of specific

documentation.
e) Testing shall conform to actual field operating conditions.
6.3 All actuators shall be visually inspected.
6.4 Dimensional check on actuators shall be carried out as per the Purchaser
approved drawings.
6.5 Chemical and mechanical properties as per relevant materials standards and this
specification shall be checked.
6.6 Complete actuator housing with internals including the open/close gas over oil
circuits of all actuators shall be subjected to a hydrostatic pressure test by applying
1.5 times the actuator design pressure for a minimum period of 2 hours. Chart
recorder shall monitor pressure. No leakage shall be permitted during the
hydrostatic test.
Document No.
Page 10 of 14
6.7 Actuator functional test shall be carried out by mounting the actuator on a test rig,
and applying the hydraulic fluid pressure. The actuator shall be successfully
stroked five times for open and close by suitably applying the hydraulic fluid
pressure through hand provided. Actuator position indication shall be checked for
correct operations during the test.
6.8 Non-destructive examination of individual actuator material and components

consisting of but not limited to castings, forgings, plate and assembly welds shall
be carried out by the Manufacturer. As a minimum, the following shall be carried
out as applicable
i) All casting of pressure containing parts shall be radiographically examined

as per ASTM E-94 and E-186/E-280 or E-446 as applicable, at quality level
2-2T. Category A, B or C defects shall not exceed the severity level for
Class 2. Category D, E, F or G defects shall not be accepted.
ii) All forgings shall be ultrasonically examined to ASTM E-609.Quality 1 will

be the minimum level of acceptance.
iii) All machined surfaces shall be liquid penetrant examined as per ASTM E-
165. Surface discontinuities shall not be acceptable.
iv) Sealing areas within the actuator body shall be completely inspected by
magnetic particle methods in accordance with ASTM E-709. Surface
discontinuities shall not be acceptable.
6.9 Valve/Actuator Assembly Test:
After testing of individual actuators has been completed, the actuators shall be
mounted on valves. Integrated valve and actuator tests shall be carried out at the
Valve Manufacturer’s Works, in compliance with the requirements stated in
Purchaser Specification for Ball Valves enclosed with the material
requisition/purchase order.
indicated in Cl. 6.1 to 6.9 above at Manufacturer’s works prior to shipment/Valve
manufacturer’s shop. Manufacturer shall give reasonable access and facilities
required for inspection to the Purchaser’s Inspector.
Purchaser reserves the right to require additional testing at any time to confirm or
further investigate a suspected fault.
The cost incurred shall be to Manufacturer’s account. In no case shall any action of
Purchaser’s Inspector relieve the Manufacturer of his responsibility for material,
design, quality or operation of the actuators. Inspection and tests
performed/witnessed by the Purchaser’s Inspector shall in no way relieve the
Manufacturer’s obligation to perform the required inspection and tests.
7.0 SHIPPING
7.1 All threaded and flanged opening shall be suitably protected to prevent entry of
foreign material.
Document No.
Page 11 of 14
7.2 The actuator shall be supplied pre-assembled except piping/tubing, actuator,

actuator control unit, tanks and other accessories shall be packed separately.
7.3 Protective grease oil coating shall be applied on the surface to protect them from
rusting.
7.4 Package shall be marked legibly with suitable marking ink the following:
a) Order number
b) Package number
c) Manufacturer's name
d) Model No. & Thrust
e) Tag number
f) Inspection agency name or logo
8.0 TEST CERTIFICATES/REPORTS
a) Mill test certificates relevant to the chemical analysis and mechanical

properties of the materials used for the actuator pressure containing parts
as per the relevant standards and specifications.
b) NDT reports for radiography, ultrasonic, magnetic particle and liquid

penetrant inspection.
c) Test report on operation of actuators including operating time.
d) Test report on hydrostatic test of actuators.
e) Test report on actuator/valve assembly tests.
f) All other actuator test reports and certificates as required by this

specification.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only
those actuators which have been certified by Purchaser’s Inspector shall be
dispatched from Manufacturer’s works.
9.0 PAINTING AND MARKING
9.1 Actuator surface shall be thoroughly cleaned, freed from rust and grease and
applied with sufficient coats of corrosion resistant paint suitable for
marine/industrial environment as indicated in the Actuator Data Sheet. Surface
preparation shall be carried out by shot blasting to SP-6 in accordance with “Steel
Structures Painting Council-Visual Standard SSPC-VIS-1". Manufacturer shall
indicate the type of corrosion resistant paint used in the drawings submitted for
approval.
9.2 All actuators shall be marked as per Manufacturer’s standard and shall have a
permanently attached stainless steel plate with the following, as a minimum, detail:
- Tag Nos.
- Manufacturer’s Name
Document No.
Page 12 of 14
- Actuator Type, Model No., Serial No.

- Suitable for mounting on Valve __” Size, ___ ANSI Rating of Ball Valve
- Max. Allowable operating pressure or voltage.
- Area Classification in which the equipment can be used.
- Actuator characteristics data.
- Inspection agency name or logo
9.3 All threaded and flanged opening shall be suitably protected to prevent entry of
foreign material. The actuator shall be supplied pre-assembled.
10.0 SPARES AND SPECIAL TOOLS
10.1 Manufacturer shall furnish list of recommended spares and accessories for
actuators required during start-up and commissioning.
10.2 Manufacturer shall recommend and quote separately the spares for actuators
required for two years of normal operation and maintenance.
10.3 In addition, Manufacturer shall recommend and quote unit price separately for the
special tools required for the operation and maintenance of the actuators.
11.0 DOCUMENTATION
a) General arrangement drawings (GAD) and sectional drawings with

materials list for actuators clearly showing all design features.
b) Technical catalogs giving technical specification and other information for

each type of actuators and its accessories.
c) Schematic diagrams showing the complete actuator control circuit.
d) Typical installation drawings complete with valve assembly.
e) Actuator sizing calculations.
f) Details of gas over oil circuit with complete sequencing of port from open to
close and close to open position.
g) Details of the hydraulic (oil) fluid proposed for filling the actuators.
h) Details of corrosion resistant paint to be applied on the actuator surface.
i) Reference list of similar supplies of actuators with all relevant details

including Project, Year, Client, Location, Size, Rating of valve, Model
Number, Type, Torque out put details, Service, etc. wherein the actuators
have been installed in the last five years.
a) A detailed specification sheet for valve actuator providing all the details
regarding type, materials of construction for various parts etc.
b) Installation drawing complete with valve assembly.
Document No.
Page 13 of 14
c) Actuator sizing calculations including relation between required torque of

valve and actuator output torque.
f) Information asked for vide section 3.0 of this specification and actuator
sizing as per Actuator Data Sheet.
g) Drawing showing connections by Purchaser (piping, electrical etc.).
h) Wiring diagram (actuator electrical circuitry) incorporating latching of

momentary signals, remote/local switch, limit switches.
i) Junction box terminal block nos. for I/O signals.
j) Parts list.
k) Recommended spare parts with prices.
l) Assembly details (Valve & Actuator).
m) Traceability report for hydrotest of gas / hydraulic cylinder shall be provided.
11.2 Within three weeks of placement of order, the Manufacturer shall submit four
copies of, but not limited to, the following drawings, documents and specifications
for Purchaser’s approval.
a) Documents as per Cl. 11.1 a) thru i)
b) Welding procedures, testing procedures and QA/QC Procedures.
Test certificates and certificates from statutory bodies.
Manufacture of actuators shall commence only after approval of the above

documents. Once Purchaser has given the approval, any change in design,
material and method of manufacture shall be notified to Purchaser whose approval
in writing of all changes shall be obtained before the actuator is manufactured.
11.3 Within 30 days from the approval date, Manufacturer shall submit to Purchaser one
reproducible and six copies of all approved drawings, documents and
specifications as listed in Cl. 11.2 above.
11.4 Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six
copies of the following:
a) Test certificates/reports as listed in clause 8.0 of this specification.
b) Manual for installation, erection instructions, and maintenance & operation

instructions including a list of recommended spares for the actuators.
c) Complete assembly drawing of the ball valve matching with the actuator
offered.
11.5 The approval of these drawings/documents will not absolve vendor of the
responsibility with respect to correct operation of the actuator.
11.6 Manufacturer's quotation, catalogues, drawings, operating and maintenance

manuals etc. shall be in English language.
Document No.
Page 14 of 14
GAS COMPOSITION
S.No. COMPONENTS Gas Composition, Mol%

1. C1 As per process
4. IC4 As per process
5. NC4 As per process
6. IC5 As per process

7. NC5 As per process
9. N2 As per process
10. CO2 As per process
11. H2S As per process

12. Total Sulphur As per process
13. Total As per process
HYDRAULIC ACTUATORS A286-000-11-42-SP-0011, Rev. B
(MANUALLY OPERATED) Page 1 of 8

SPECIFICATION FOR
HYDRAULIC ACTUATORS
(MANUALLY OPERATED)
B 09.08.12 REVISED & RE-ISSUED AS JOB SPECIFICATION SG SRG MSG
A 12.06.12 ISSUED FOR COMMENTS SG NR MSG

Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Hydraulic Actuator Spec_rev B Copyright EIL – All rights reserved
(MANUALLY OPERATED)
Page 2 of 8
CONTENTS
1.0 SCOPE ....................................................................................................................................... 3
2.0 REFERENCE DOCUMENTS ................................................................................................. 3
3.0 MATERIALS .............................................................................................................................. 4
4.0 DESIGN AND CONSTRUCTION ........................................................................................... 4
5.0 INSPECTION AND TESTS ..................................................................................................... 5
6.0 EXTENT OF INSPECTION AND TESTING ......................................................................... 6
7.0 TEST CERTIFICATES/REPORTS ........................................................................................ 7
8.0 PAINTING AND MARKING ..................................................................................................... 7
9.0 SPARES AND SPECIAL TOOLS .......................................................................................... 8
10.0 DOCUMENTATION.................................................................................................................. 8
(MANUALLY OPERATED)
Page 3 of 8
1.0 SCOPE
This specification covers the minimum requirements for design, manufacture,

inspection and testing of quarter turn hydraulic actuators suitable for operation of ball
valves in pipeline/piping systems handling hydrocarbons in gaseous phase.
This specification shall be read in conjunction with valve specification and data sheets.
Reference has been made in this specification to the latest edition of the following
Codes, Standards and Specifications.
a) ASME B 31.3 : Chemical Plant and Petroleum Refinery Piping
b) ASME B 16.5 : Steel Pipe Flanges and Flanged Fittings
c) ASME Sec VIII : Boiler and Pressure Vessels Code
d) MSS – SP – 101 : Part-Turn Valve Actuator Attachment – Flange and

Driving Component Dimensions and Performance
Characteristics
e) SSPC-VIS-1 : Steel Structures Painting Council Visual Standard
f) PNGRB Regulations : Technical Standards & Specifications including

(GSR808E) safety standards for natural gas pipelines.
g) OISD 138 : Inspection of Cross Country Pipelines-Onshore
h) API RP 1102 : Steel Pipelines Crossing Railroads & Highways
j) API Std. 1104 : Welding of Pipelines and Related Facilities
k) Petroleum Rules,1976 : Part V; Transport by Pipelines
In case of conflict between the requirements of this specification and the Codes,
Standards and Specification referred above, the order of precedence shall be as follow:
a. Data Sheets
b. Job Specifications
c. Codes and Standards
Contractor shall refer the matter to the Client / Consultant for clarification and only after
obtaining the approval in writing, the same should proceed with the manufacture of the
items in question.
(MANUALLY OPERATED)
Page 4 of 8
3.0 MATERIALS
Actuators shall be supplied with SS 316 stainless steel trim. Materials of all parts and
seals shall be compatible with the operating hydraulic fluid. All materials shall be
suitable for the ambient conditions indicated in the Actuator Data Sheets.
4.1 Hydraulic actuator shall be of rotary vane mechanism type or double acting scotch yoke
mechanism type with pistons and shall maintain the selected valve position fully open
or closed with pressure equalized.
4.2 Actuator body shall be designed to ASME B31.3 and all body joints shall be in
accordance with ASME Section VIII, Division 1.
4.3 Actuator shall be suitable for direct mounting on the ball valves without changing the
standard top works of the valve and shall have the capability to be mounted or removed
from the valve when the valve is in service.
4.4 All pressure and load carrying components in the actuator shall be designed to
withstand the maximum output thrust without affecting valve performance.
4.5 Actuator shall be sized considering the break-away thrust corresponding to maximum
differential pressure of valve ANSI Rating required at the valve stem to open and close
the valve. A factor of safety of 1.25 shall be considered in the actuator design. Due
correction factor shall be applied for the temperature and pressure ratings.
4.6 Actuator maximum thrust shall be limited such that the allowable stress values of valve
stem is not exceeded during valve operation.
4.7 Actuator – valve interface shall meet the applicable requirements of MSS-SP-101. To
assure geometrically accurate valve/actuator alignment, a centering ring as required
may be provided.
4.8 Actuator shall be capable of opening or closing the valves within the operating time
indicated in the Actuator Data Sheet and specification of valves. Provision shall be
made for slower actuation during maintenance and field testing activities.
4.9 Actuator shall be provided with valve position switch/indicator which shall clearly show
whether the valve in open, close or in partially open position.
4.10 Mechanical stops shall be provided to limit the actuator travel independently from any
valve stops.
4.11 Threading connection shall be NPT as per ASME B 2.1 and flange connection shall be
as per ASME B 16.5/ASMB B 16.47 Series A. The tubing, fitting and valves shall be
SS 316 stainless steel. All the fittings should be of dielectric type. All tubing shall be
properly supported and shielded from damage by a suitable protective cover.
4.12 Each actuator shall be provided with a manual hydraulic module incorporating a
positive displacement piston pump, directional control valve, hydraulic reservoir, level
indicator and pressure relief. In addition, by-pass for high speed operation shall also be
provided. This manual hydraulic pump module shall be mounted as an integral
component of actuator.
(MANUALLY OPERATED)
Page 5 of 8
4.13 Hydraulic reservoir required to be provided as a part of the manual hydraulic pump
module shall be manufactured from 316 stainless steel and be fitted with internal weir
/baffles to prevent return oil channeling directly to pump suction, level gauge with
isolating valves, inspection/cleaning cover and vent/breather.
4.14 Positive displacement hand pump to be provided as a part of the manual hydraulic
pump module shall eliminate cavitations or sucking air. It shall be possible to stroke the
hand-pump at any speed without drawing a vacuum into the pumping chamber. The
hand pump shall be provided with an individual suction filter, block valves, pressure
gauge, relief valve and check valve.
4.15 Hydraulic fluid used shall be oil based and shall have a cleanliness level of NAS 1638,
Class 6. The actuator shall be supplied filled with hydraulic fluid approved by
Purchaser.
4.16 Actuator and its accessories shall be suitable for outdoor installation and shall be
provided with weather proof enclosures as per NEMA 4X or equivalent.
4.17 All compartments and housing containing electrical devices such as switches, etc. shall
be intrinsic safe suitable for Zone- 2, group IIA/IIB, Temp. Class T3 as per IEC/IS.
4.18 Actuators shall be provided with limit switches for open and close positions. Limit switch
shall be of proximity type with NAMUR design. Limit switch shall be provided with
integral junction box having 2 no. of ½” NPT F cable entries. One cable entry shall be
plugged. Flying leads shall not be acceptable. Limit switch shall be Non-contact type.
Two no. of potential free NO contacts shall be provided at AV cabinet for open and
close status of the valve.
4.19 All mounting accessories needed for installing the actuator and its accessories are in
manufacturer's scope of supply.
4.20 The interconnecting cabling, interconnecting pipe work between the actuator and the
manual hydraulic module, adapters, tubing, cable glands, junction box as required are
in manufacturer's scope of supply.
4.21 Contractor shall indicate actuator model no., valve torque, actuator torque figures in a
tabular form and shall be given for the different valve positions. The torque figure shall
be expressed in Newton Meters (NM).
5.1 The actuator Manufacturer shall perform all inspection and tests as per the
requirements of this specification and the relevant codes at his Works, prior to shipment
to valve Manufacturer’s works. Such inspection and tests shall be, but not limited to,
the following:
a) All actuators shall be visually inspected.

b) Dimensional check shall be carried out as per the Purchaser approved
drawings.
c) Chemical and mechanical properties as per relevant materials standards and
this specification shall be checked.
d) Complete actuator housing with internals including the open/close hydraulic
circuits of all actuators shall be subjected to a hydrostatic pressure test by
(MANUALLY OPERATED)
Page 6 of 8
applying 1.5 times the actuator design pressure for a minimum period of 2
hours. Chart recorder shall monitor pressure. No leakage shall be permitted
during the hydrostatic test.
e) Actuator functional test shall be carried out by mounting the actuator on a test
rig, and applying the hydraulic fluid pressure. The actuator shall be successfully
stroked five times for open and close by suitably applying the hydraulic fluid
pressure through hand provided. Actuator position indication shall be checked
for correct operations during the test.
f) Non-destructive examination of individual actuator material and components
consisting of but not limited to castings, forgings, plate and assembly welds
shall be carried out by the Manufacturer. As a minimum, the following shall be
carried out as applicable. All NDT test shall be witness by TPI as per approved
QAP.
i) All casting of pressure containing parts shall be radio graphically examined as
per ASTM E-94 and E-186/E-280 or E-446 as applicable, at quality level 2-2T.
Category A, B or C defects shall not exceed the severity level for Class 2.
Category D, E, F or G defects shall not be accepted.
ii) All forgings shall be ultrasonically examined to ASTM E-609. Quality 1 will be
the minimum level of acceptance. For heat treatment of forging material: Temp
chart shall be signed & witness by TPIA, and also power failure log shall be
maintained.
iii) All machined surfaces shall be liquid penetrate examined as per ASTM E-165.
Surface discontinuities shall not be acceptable.
iv) Sealing areas within the actuator body shall be completely inspected by
magnetic particle methods in accordance with ASTM E-709. Surface
discontinuities shall not be acceptable.
g) Valve/Actuator Assembly Test
After testing of individual actuators has been completed, the actuators shall be
mounted on valves. Integrated valve and actuator tests shall be carried out at
the Valve Manufacturer’s Works, in compliance with the requirements stated in
Purchaser Specification for Ball Valves enclosed with the material
requisition/purchase order.
indicated in Cl. 5.1 above at Manufacturer’s works prior to shipment. Manufacturer
shall give reasonable access and facilities required for inspection to the Purchaser’s
Inspector. Purchaser reserves the right to require additional testing at any time to
confirm or further investigate a suspected fault. The cost incurred shall be to
Manufacturer’s account. In no case shall any action of Purchaser’s Inspector relieve the
Manufacturer of his responsibility for material, design, quality or operation of the
actuators. Inspection and tests performed/witnessed by the Purchaser’s Inspector shall
in no way relieve the Manufacturer’s obligation to perform the required inspection and
tests.
6.0 EXTENT OF INSPECTION AND TESTING
All actuators shall be tested in accordance with the requirements of Section 5.0 of this
specification. Factory acceptance test (FAT) & Site Acceptance test (SAT) shall be
performed for all actuators.
(MANUALLY OPERATED)
Page 7 of 8
7.0 TEST CERTIFICATES/REPORTS
a) Mill test certificates relevant to the chemical analysis and mechanical properties
of the materials used for the actuator pressure containing parts as per the
relevant standards and specifications.
b) NDT reports for radiography, ultrasonic, magnetic particle and liquid penetrant
inspection.
c) Test report on operation of actuators including operating time.
d) Test report on hydrostatic test of actuators.
e) Test report on actuator/valve assembly tests.
f) All other actuator test reports and certificates as required by this specification.
g) Third Party Inspection Agency SHALL ISSUE 3.2 CERTIFICATES AS PER EN

10204.
The certificates shall be valid only when signed by Purchaser’s Inspector. Only those
actuators which have been certified by Purchaser’s Inspector shall be dispatched from
Manufacturer’s works.
8.0 PAINTING AND MARKING
8.1 Actuator surface shall be thoroughly cleaned, freed from rust and grease and applied
with sufficient coats of corrosion resistant paint suitable for marine/industrial
environment as indicated in the Actuator Data Sheet. Surface preparation shall be
carried out by shot blasting to SP-6 in accordance with “Steel Structures Painting
Council-Visual Standard SSPC-VIS-1". Manufacturer shall indicate the type of
corrosion resistant pain used in the drawings submitted for approval.
8.2 All actuators shall be marked as per Manufacturer’s standard and shall have a
permanently attached stainless steel plate with the following, as a minimum, details:
- Tag Nos.
- Manufacturer’s Name
- Actuator Type, Model No., Serial No.
- Suitable for mounting on Valve __” Size, ___ ANSI Rating Ball Valve
- Area Classification
8.3 All threaded and flanged opening shall be suitably protected to prevent entry of foreign
material. The actuator shall be supplied pre-assembled.
(MANUALLY OPERATED)
Page 8 of 8
9.0 SPARES AND SPECIAL TOOLS
9.1 Manufacturer shall recommend and quote separately the spares for actuators required
for commissioning and two years of normal operation.
9.2 In addition, Manufacturer shall recommend and quote unit price separately for the
special tools required for the operation and maintenance of the actuators.
10.0 DOCUMENTATION
a) QAP, Data sheet, Procedure for FAT & SAT, General arrangement drawings
and sectional drawings with materials list for actuators clearly showing all design
features.
b) Technical catalogs giving technical specification and other information for each
type of actuators and its accessories.
c) Schematic diagrams showing the complete actuator control circuit.
d) Typical installation drawings complete with valve assembly.
e) Actuator sizing calculations.
f) Details of hydraulic circuit with complete sequencing of port from open to close
and close to open position.
g) Details of the hydraulic fluid proposed for filling the actuators.
h) Details of corrosion resistant paint to be applied on the actuator surface.
i) Clause wise list of deviations from the requirements of this specification, if any.
j) Reference list of similar supplies of actuators with all relevant details including
Project, Year, Client, Location, Size, Rating, Service, etc. wherein the actuators
have been installed in the last three years.
10.2 Within three weeks of placement of order, the Manufacturer shall submit the following
drawings, documents and specifications for Purchaser’s approval.
a) Documents as per Cl. 10.1 a) thru i)
b) Welding procedures, testing procedures and QA/QC Procedures.
Manufacture of actuators shall commence only after approval of the above documents.
Once Purchaser has given the approval, any change in design, material and method of
manufacture shall be notified to Purchaser whose approval in writing of all changes
shall be obtained before the actuator is manufactured.
10.3 Manufacturer shall submit to Purchaser the copies of all approved drawings,
documents and specifications as listed in Cl. 10.2 above.
(MANUALLY OPERATED)
Page 9 of 8
10.4 Prior to shipment, Manufacturer shall submit the following to Purchaser:
a) Test certificates/reports as listed in clause 7.0 of this specification.
b) Manual for installation, erection instruction and maintenance & operation

instruction including a list of recommended spares for the actuators.
ADDENDUM DOCUMENT No.
TO A286-000-11-42-AD-01 Rev. 0
STANDARD SPECIFICATIONS
Page 1 of 11

ADDENDUM TO STANDARD SPECIFICATIONS

(Pipeline Engineering Department)
0 07.09.2012 ISSUED AS JOB SPECIFICATION GT NR MSG

Date Purpose
No by by by
TO A286-000-11-42-AD-01 Rev. 0
Page 2 of 11
AMENDMENTS/ADDITIONAL REQUIREMENTS
1.0 General
i. The word “company” stands replace by “owner/ consultant". This is
applicable for all standard specifications.
Specification No. : 6-71-0016, Rev 4
Title : Specification for pipeline Lubricated plug valves

(Onshore)
Following amendments/additional requirements shall be applicable:
2.0 Refer Clause No. 3.4, ” The valves specified to be used for … the standard shall
complied with “ , Page 5 of 13 stands replaced by following .
i. Charpy V-notch on each heat of base material shall be conducted for all pressure
containing parts such as body, end flanges, welding wend as well as bolting material for
pressure containing parts .
ii. For normal temperature service piping class charpy V-notch test shall be conducted at -
20°C. The average absorbed energy value of full sized specimens shall be 35 J. The
minimum impact energy value of specimen shall not be less than 28J
iii. For LTCS material piping class charpy V-notch test standard shall be conducted as per
the applicable material standard., how ever the test temperature shall be no case lower
than (-) 45°C( i. e test temperature shall be as per material standard or (-) 45°C which
ever is less.)
iv. In addition to above for LTCS material piping class 150#, 300#, 600# and 900# Charpy
V-notch test shall be conducted at -20°C. The average absorbed energy value of full
sized specimens shall be 35 J. The minimum impact energy value of specimen shall not
be less than 28J
3.0 Refer Clause No. 4.15, ”The impact test of weld material shall be as per addendum
requirement” of page no. 8 of 13.
4.0 Refer Clause No. 5.1.7, add the following clause ”In addition to above pneumatic
testing shall be carried out at 95 bar (g) for 600# pressure rating valves, using
nitrogen for 5 minutes” page 9 of 13.
5.0 Refer Clause No. 5.1.9 first paragraph of page no. page no. 10 of 13, “clause no
shall be read as 5.1.8”.,
Add the following clause ”In addition to above helium leak test shall be carried out
as per API 6D. The duration and test procedure shall be same as supplementary
air seat test”.
Title : Standard Specification For check valves Pipeline

(Onshore)
6.0 Refer Clause No. 3.3, ” The valves specified to be used for … the standard shall
complied with “ , Page 5 of 10 stands replaced by following .
TO A286-000-11-42-AD-01 Rev. 0
Page 3 of 11
containing parts such as body, end flanges, welding wend as well as bolting material for
pressure containing parts .
ever is less.)
iv. In addition to above for LTCS material piping class charpy V-notch test shall be
conducted at -20°C. The average absorbed energy value of full sized specimens shall
be 35 J. The minimum impact energy value of specimen shall not be less than 28J
7.0 Refer Clause No. 5.1.6, add the following clause ”In addition to above pneumatic
testing shall be carried out at 95 bar (g) for 600# pressure rating valves, using
nitrogen for 5 minutes” page 7 of 10.
8.0 Refer Clause No. 5.1.7,page 7 of 10 Add the following clause ”In addition to above
helium leak test shall be carried out as per API 6D. The duration and test
procedure shall be same as supplementary air seat test”.
Title : Standard Specification For Long radius bend for

Onshore Pipeline
9.0 Refer Clause No. 9.3. (e), page 10 of 11 the clause charpy ‘V’ notch test
temperature shall be same as specified in …….. out side radius of bend” “ stands
replace by following .
The charpy v notch impact test shall be carried out at (-) 20ºC & 0 ºC. The
minimum all heat average full size absorbed energy value (based on a set of three
specimens) for transverse body specimen, weld and HAZ shall be as per below
table.

Test temp. Avg. Values Individual Values Avg. Values Individual
Values
(-) 20ºC 35 J 28 J 27 J 22 J
0ºC 100 J 80 J 40 J 32 J
In addition the lowest individual absorbed energy value of the three specimens shall
not be less than 80% of the value specified for body, weld and HAZ.
10.0 Refer Clause No. 9.3. (f) ,page 11 of 11 the clause hydro test “ bend shall be
hydrostatically tested …….corresponding to 90% of SMYS of pipe material” stands
replaced by “ bend shall be hydrostatically tested to test pressure that shall result
in hoop stress corresponding to 95% of SMYS, computed based on the formula
mentioned in API Spec 5L para 10.2.6.5
TO A286-000-11-42-AD-01 Rev. 0
Page 4 of 11
Add the following clause

“Calibration of pressure gauge shall be done at start of an each shift (12 hrs max.)
& calibration of hydro tester with 1.6 mm TDH shall be carried out at beginning of
each shift”
Title : Standard Specification For flanges and welded

fittings (sizes DN 450 mm (18”) & above)
Following amendments/additional requirements shall be applicable
11.0 Refer Clause No. 4.3, page 5 of 8 the entire clause “for flanges and fittings ….
Shall be complied with “ stands replaced by following
i. For normal temperature service piping class charpy V-notch test shall be conducted at -
ii. For LTCS material piping class charpy V-notch test standard shall be conducted as per
ever is less.)
iii. In addition to above for LTCS material piping class charpy V-notch test shall be
12.0 Refer Clause No. 5.0,page 5 of 8, design and manufacture , add the following
clause
i. The (+)ve tolerance in the Inner Diameter of flanges shall be zero.

ii. The (-)ve tolerance in wall thickness of fittings shall be zero.
Title : Standard Specification For seamless fittings and

flanges (sizes upto DN 400 mm (16”))
13.0 Refer Clause No. 4.3, page 5 of 8 the entire clause “for flanges and fittings ….
Shall be complied with “ stands replaced by following
ever is less.)
14.0 Refer Clause No. 5.0, design and manufacture , add the following clause
TO A286-000-11-42-AD-01 Rev. 0
Page 5 of 11
i. The (+)ve tolerance in the Inner Diameter of flanges shall be zero.

ii. The (-)ve tolerance in wall thickness of fittings shall be zero.
Title : Standard Specification For flow tees for onshore

pipelines
15.0 Refer Clause No. 4.4, of page 5 of 8 the entire clause “for flow tees specified…
shall be complied” stands replaced by following
ever is less.)
Title : Standard Specification For Insulating joints onshore

pipelines
16.0 Refer Clause No. 3.4, of page 5 of 10 the entire clause “for insulating joints…..shall
be complied” stands replaced by following
containing parts such as pipe piece, retain ring of insulating joints
ever is less.)
iv. In addition to above for LTCS material piping class charpy V-notch test shall be
TO A286-000-11-42-AD-01 Rev. 0
Page 6 of 11
Title : Standard Specification For scraper trap (onshore)
17.0 Refer Clause No. 3.4, of page 5 of 10, the entire clause “for scraper trap
specified… shall be complied” stands replaced by following
ever is less.)
18.0 Refer Clause No. 4.0, design and construction requirement of page 5 of 10 add the
following clause
i. The scraper trap manufacturer shall have “U” Stamping of fabrication yard.
ii. Double acting clamping type Quick Opening End Closure is not acceptable.
Title : Standard Specification For field joint coating

(onshore)
19.0 Refer Clause No. 3.3.1, of page 5 of 12, the thickness of heat shrinkable wrap
wound stands replaced by following :
Pipe size (Specified OD) Total thickness of heat shrinkable wrap

wound sleeve (mm)
On pipe body On weld bead
(minimum) (minimum)
Up to 30” (762 mm) 3.5 3.0
From 32” and above 3.7 3.2
Title : Standard Specification For Pipeline Construction

(Onshore)
TO A286-000-11-42-AD-01 Rev. 0
Page 7 of 11
20.0 Refer Clause No. 2.0, Reference Codes, Standards and specifications, Page 5
of 37.
i. “6th Para of Cl. No.2.1; “OISD-141 Design and construction requirement for
cross country pipeline” stands deleted”.
ii. “7th Para of Cl. No.2.1; “OISD-226 Natural gas transmission pipelines and
city gas distributions network” stands deleted”.
21.0 Refer Clause No. 4.0, ROU clearing and grading, Page 9 of 37.
Add the following clauses.

i. “Draining of pollutants onto the land or into a body of water are not
permitted. All waste material must be collected and removed by the
contractor to an approved disposal area on an ongoing basis”.
ii. “Contractor shall carry out pre-construction survey and post construction
survey. The entire data i.e. pipeline co-ordinates, geographical and UTM
co- ordinates of all turning points / starting / ending points etc. shall be
taken from DGPS. Pipeline co-ordinates shall be entered in pipe book
strictly from DGPS. The data from DGPS should be of latest version of
ARC GIS (ESRI) and compatible to upload the entire survey data from
PIMS. Ripper survey is to be carried out during grading for special
crossings and valley terrains. Grading reports are to be issued there after
indicating the slope, slope breakers etc”.
22.0 Refer Clause No. 6.4, Pipeline Normal cover. , Page 17 of 37.
i. “The pipeline minimum cover indicated in page no. 17 of 37 stands replaced by

following”:
Table-1
Sl.
Location Minimum Cover (m)
No.
1 Industrial, commercial and residential area 1.2
2 Rocky terrain 1.0
3 Minor water crossing / canal /drain /nala /stream 1.5
River crossings (Bank width < 50 m)
(Below lowest bed -Scour depth not known) 2.5

4
(Below Scour -Scour depth known) 1.5
Other River crossings (Bank width >50 m)

5
(Below lowest bed -Scour depth not known)) 3.5 (for normal soil)
TO A286-000-11-42-AD-01 Rev. 0
Page 8 of 11
Sl.
Location Minimum Cover (m)
No.
1.5 (for rocky strata)
(Below Scour -Scour depth known)) 2.5 (for normal soil)
1.5 (for rocky strata)
6 Water crossing by HDD 2.5 (Below Scour)
7 Cased/ uncased road crossing/ Station approach 1.2
8 Cased railway crossing 1.7
9 Drainage, ditches at roads/ railway crossings 1.2
10 Marshy land and Creek area 1.5
1.5(below predicted
11 Areas of brick kiln
excavation level)
23.0 Refer Clause No. 9.1, Lowering in Trench , Page 23 of 37.

Add the following clause
i. “The pipeline shall be lowered into trench as soon as the coating is hardened
sufficiently so that the lowering will not cause not holidays. This shall be
checked by picking the pipe up after it has been lowered in and checking with
holiday detector. If this check shows holidays, the pipe must be lowered to skids
until it has had sufficient time to properly harden”.
24.0 Refer Clause No. 10.0, back filling , Page26 of 37.
Add the following clauses.
i. “Immediately after the pipe has been lowered, it shall be weighted by filling the
ditch over the pipe with back fill material. After the ditch has been filled to the
level of surrounding ground, one tread of heavy tractor shall run over the back
fill. This tamping operation is not to be done through rocky land where the
coating might be damaged or through the sections where drainage tile is
encountered and might be damaged. After the above tamping operation, the
remaining backfill shall be spread over the pipeline ditch in a manner acceptable
to owner and land owner”.
ii. “Upon completion of clean-up operation, all the right of way damage claim will
be settled promptly with land owners. Representative of both contractor and
owner will present in the settlement of all claims and for signing of releases by
land owner or tenant on approved forms”.
iii. “Clean-up progress will be reported to show only the amount of continuous
clean-up from the staring point to the first section skipped. The only exception of
the above is that clean-up progress will be reported as completion deduction of
TO A286-000-11-42-AD-01 Rev. 0
Page 9 of 11
skips which may be made around short areas with the written approval of owner
when ground conditions justify the skip.
It is understood that when skips are permitted, contractor agrees to bring men
and equipment back to complete clean-up at such skips as soon as ground
permission permit or as soon as owner may request at no additional cost”.
Title : Standard Specification For construction of pipeline

crossing Road, rail road and minor water crossings
(onshore)
25.0 Refer Clause No. 6.13, of page 10 of 11, hydro test pressure of , “ the test
procedure shall be result in hoop stress of 90% of SMYS” stands replaced by “ the
test procedure shall result in a hoop stress in pipe corresponding to 95 % of
SMYS” .
Title : Standard Specification For major water crossings

(onshore)
26.0 Refer Clause No. 9.0, of page 12 of 13, post installation hydro test, “ the test
procedure shall be result in hoop stress of 90% of SMYS” stands replaced by “ the
test procedure shall result in a hoop stress in pipe corresponding to 95 % of
SMYS”
Title : Standard Specification For pipeline markers
27.0 Refer Clause No. 6.0, of page 5 of 6, pipeline markers for road and minor water
crossings shall be as per below.
- Other road crossings -2 Nos. minimum
- Minor water crossings (less than 15 meter width) – 2 nos. minimum
- No pipeline warning shall be required for cart track.
TO A286-000-11-42-AD-01 Rev. 0
Page 10 of 11
Title : Standard Specification For Documentation of

pipeline
28.0 Refer Clause No. 3.2, of page 7 of 9, the surveyor shall daily take care of all
measurements required such as not limited to , add following clause
– Location and details of buried services.
Title : Technical notes for pipe
29.0 Refer Clause No. 1.17.5, of page 6 of 9, charpy test clause “ for carbon steel …
with minimum of 19J (15ftlb)” stands replaced by following
i. For normal temperature service piping class charpy V-notch test shall be conducted at -20°C.
The average absorbed energy value of full sized specimens shall be 35 J. The minimum
impact energy value of specimen shall not be less than 28J
ii. For LTCS material piping class charpy V-notch test standard shall be conducted as per the
applicable material standard., how ever the test temperature shall be no case lower than (-)
45°C( i. e test temperature shall be as per material standard or (-) 45°C which ever is less.)
iii. In addition to above for LTCS material piping class charpy V-notch test shall be conducted at -
20°C. The average absorbed energy value of full sized specimens shall be 35 J. The minimum
impact energy value of specimen shall not be less than 28J
Title : Technical notes for valves
30.0 Refer Clause No. 6.0, 6.1, 6.2, 6.3, 6.4 and 6.5 of page 12 of 12, Radiography of
cast valves, stands replaced by followings:
i. Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer.
ii. Body castings of all valves shall be radiographically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B16.34. The extent of the
radiography shall be as under:
Pressure Class Rating & Size Extent of Radiography
TO A286-000-11-42-AD-01 Rev. 0
Page 11 of 11
iii. Radiography shall be performed after the final heat treatment also.
iv. All castings shall be wet magnetic particle inspected 100% of the internal surfaces. Method
and acceptance shall comply with ASME B16.34.
v. All valves, with body fabricated from plates or made by forgings, shall be ultrasonically
examined in accordance with the procedure and acceptance standard of Annexure E of ASME
B16.34.
vi. All forgings shall be wet magnetic particle inspected 100% of the internal surfaces.
vii. Method and acceptance shall comply with ASME B16.34.
viii. Bodies and bonnets made by welded assembly of segments of castings, forgings, plates or
combinations thereof shall be examined, as applicable, by methods of clause no. 24.(ii). for
cast components or 24.(V) for forged components and plates.
Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.4 or ASME B31.8 as applicable and API 1104.
31.0 Refer Clause No. 2.1 of page 1 of 2 of 6-44-0052-A3-Rev. 6, “cryogenic test

stands deleted.:
JOB SPECIFICATION FOR GEO DOCUMENT No.
TEXTILE BAGS FOR ANTI A286-000-11-42-SP-0013 Rev. 0
BUOYANCY Page 1 of 5

esglkuk - cfBaMk ikbiykbZu ifj;kstuk
JOB SPECIFICATION FOR GEO TEXTILE

BAGS FOR ANTI BUOYANCY
0 09.08.12 ISSUED AS JOB SPECIFICATION MPS NR MSG

Date Purpose
No by by by

TEXTILE BAGS FOR ANTI A286-000-11-42-SP-0013 Rev. A
CONTENTS
1.0 SCOPE....................................................................................................................................... 3
2.0 DESIGN ..................................................................................................................................... 3
3.0 MATERIAL................................................................................................................................. 4
4.0 DELIVERY, STORAGE AND HANDLING ............................................................................ 4
5.0 MARKING .................................................................................................................................. 4
6.0 OTHER TECHNICAL REQUIREMENTS.............................................................................. 4
7.0 INSTALLATION ........................................................................................................................ 4
8.0 DOCUMENTATION ................................................................................................................. 5

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”
three layer polyethylenes (3LPE) coated pipeline carrying natural gas 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 the following:-
Maximum Geotextile
Pipe O.D. Pipe Wall Thickness
Bag Spacing
Inch (mm) mm m ( C/C )

36” (914) 13.0 2.8
36” (914) 15.9 3.2
36” (914) 19.1 3.8
24” (610) 8.7 4.6
24” (610) 10.3 5.1
24” (610) 12.7 6.1
18” (457) 7.1 8.6
18” (457) 8.7 10.0
18” (457) 10.3 11.9
18” (457) 12.7 16.7
12.75” (323.8) 6.4 6.5
12.75” (323.8) 7.9 8.4
8.625” (219.1) 6.4 10.6
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 and installation
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
body fabric must be a minimum of 400 gms/m2.
3.2 All material used in the fabrication of geo-textile bags such as webbing, lifting loops
(i.e. Straps), 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

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 36”/24”/18”/12”/8”, 3 layer polyethylenes (3LPE) coated line pipes. The
three layers PE coating shall be 2.0 mm thick for 8” line pipe, 2.2 mm for 12” & 18”
pipe, 2.5 mm for 24” pipe & 3.0 mm for 36” pipe.
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
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 3 LAYER DOCUMENT No.
POLYETHYLENE COATING OF A286-000-11-42-SP-0041 Rev. 0
LINEPIPES
Page 1 of 28

SPECIFICATION FOR 3 LAYER POLYETHYLENE

COATING OF LINEPIPES
B 25.06.12 REVISED & RE-ISSUED AS JOB SPECIFICATION RB NR MSG

Date Purpose
No by by by
Format No. 8-00-0001-F1 Rev. 0
LINEPIPES
Page 2 of 28
Abbreviations:

DIN Deutsches Institut für Normung
ISO International Organization for Standardization
PQT Procedure Qualification Tests
DSC Differential Scanning Calorimetry
FBE Fusion Bonded Epoxy
PE Polyethylene
ESCR Environmental Stress Crack Resistance

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Page 3 of 28
CONTENTS
1.0 SCOPE
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
11.0 HANDLING, TRANSPORTATION AND STORAGE
12.0 REPAIR OF COATING
13.0 MARKING
14.0 QUALITY ASSURANCE
ANNEXURE-I LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS

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Page 4 of 28
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.
Reference has also been made to the latest edition (edition enforce at the time of issue of
enquiry) of the following standards, codes and specifications. 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 Power Frequencies.
b. ASTM D-257 : Standard Test Methods for D-C Resistance or Conductance of
Insulating Materials.
c. ASTM D-543 : Standard Practices for evaluating the 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 : Standard Test Method for Melt Flow Rates of Thermoplastics
by Extrusion plastometer
h. ASTM D-1525 : Standard Test Method for Vicat Softening Temperature of
Plastics
i. ASTM D-1603 : Standard Test Method for Carbon Black in Olefin Plastics
j. ASTM D-1693 : Standard Test Method for Environmental Stress Cracking of
Ethylene Plastics
k. ASTM D-2240 : Standarad Test Method for Rubber Property – Durometer
Hardness
l. ASTM D-3895 : Standarad Test Method for Oxidative-Induction Time of
Polyolefinsby Differential Scanning Calorimetry
m. ASTM G-42 : Standard Test Method for Cathodic Disbonding of
Pipeline Coatings Subjected to Elevated
Temperatures
n. API RP 5L1 : Recommended Practice for Railroad Transportation of
Linepipe.
o. API RP 5LW : Transportation of Line Pipe on Barges and Marine Vessels

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Page 5 of 28
p. DIN EN 10204 : Metallic Products – Types of Inspection Documents

q. DIN 53735 : Testing of Plastics: Determination of Melt Index of
Thermoplastics.
r. IEC 454 – 2 : Specification for Pressure-Sensitive Adhesive Tapes for
Electrical Purposes.
s. ISO 8501-1 : Preparation of Steel Substrates before Application of Paints
and Related Products – Visual Assessment of Surface
Cleanliness: Part 1 – Representative Photographs of the
Change of Appearance imparted to Steel when Blast Cleaned
with different Abrasives
t. ISO 8502 – 3 : Preparation of Steel Substrates before Application of Paints

and Related Products –
Part 3 – Assessment of Dust on Steel Surfaces Prepared for
Painting (Pressure Sensitive Tape Method)
u. ISO 9002 : Quality Systems: Model for Quality Assurance in Production,
Installation and Servicing
v. ISO 11124 : Preparation of Steel Substrates Before Application of Paints
and Related Products
w. API 5L/ISO 3183 : Specification for Line Pipe
x. ASME B31.8 : Gas Transmission and Distribution Piping Systems.
y. ASME B31.4 : Liquid Transportation Systems for Hydrocarbons, Liquid
Petroleum Gas, Anhydrous Ammonia, and Alcohols
z. CSA Z245.20-02 : 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 and 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.
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-

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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
Owner/ Client.
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 topcoat. 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 Owner/ Client in accordance with provisions of Annexure I of this
specification. Contractor shall obtain prior approval from Owner/ Client 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 Infra-red 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 Owner/
Client 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 Owner/ Client 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 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

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Page 7 of 28
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. Manufacturing standard
c. Health, safety and environmental Instructions
d. Receiving inspection acceptance criteria
e. Data Sheets
f. Storage instruction.
g. Type of Material
h. Batch Number
i. Place and Date of Manufacture
j. Shelf Life/Expiry Date (if applicable)
k. Quantity
All materials noted to be without above identification shall be deemed suspect and shall be
rejected by Owner/ Client. 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.
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 (+)
65°C 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 impairing its
serviceability and properties specified.
5.2 The topcoat polyethylene used shall be a black readymade compound, fully stabilized against
influence of ultraviolet radiation (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.

LINEPIPES
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5.3.1 Properties of Epoxy Powder and Adhesive
Contractor shall choose brand of epoxy powder and adhesive as per approved vendor list 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 Z245.20-02. The colour of epoxy powder shall
be either green or dark red or any other colour approved by Owner/ Client except grey colour.
Copolymer grafted adhesive shall have the following properties:
Sl. No. Properties Unit Requirement Test Method
a. Melt Flow Rate (190°C / 2.16 kg) g/10 minutes 1.0 min. ASTM D 1238
0
b. Vicat Softening Point C 100 min. ASTM D 1525
c. Specific Gravity - 0.926 min. ASTM D 792
5.3.2 Properties of Polyethylene Compound
a. Tensile Strength @ + 25 °C N/mm2 17 min. ASTM D 638

Melt Flow Rate ASTM D 1238 or
b. g/10 minutes 0.25 min.
(190°C / 2.16 kg) DIN 53735
0.926 min.(MDPE)
c. Specific Gravity @ + 25 °C - 0.941 min. (HDPE)
ASTM D 792
d. Hardness @ + 25 °C Shore D 50 min. ASTM D 2240

Water Absorption, 24 hours,
e. % 0.05 max. ASTM D 570
@ + 25 °C
f. Volume Resistivity @ + 25°C Ohm-cm 1015 min. ASTM D 257
Dielectric withstand, 1000 Volt/sec
g. Volts/mm 30,000 min. ASTM D 149
rise @ + 25 °C
h. Vicat Softening Point 0C 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, Aluminium pan, no screen
Environmental Stress Crack
Resistance (ESCR) (for F50)
k. Hours 300 ASTM D1693
 Medium Density [Condition “C”]
300
 High Density [Condition “B”]
l. Carbon Black Content % 2 min. ASTM D 1603
5.3.3 Properties of Coating System

Bond Strength (using Type 2 Test
Assembly i.e. Dynamometer)
a. kg/cm DIN 30670
 @ 20 +/- 5°C 8.0 min
 @ 65 +/- 5°C 5.0 min
Impact Strength
(Min. of 30 impacts on body along Joules per mm of 7 min
b. DIN 30670
the length. No breakdown allowed coating thickness
when tested at 25 KV)

LINEPIPES
Page 9 of 28

Indentation Hardness
c.  @ 23 +/- 2°C mm 0.2 max DIN 30670
 @ 70 +/- 2°C 0.3 max
d. Elongation at Failure % 300 min. DIN 30670
e. Coating Resistivity (*) Ohm – m2 108 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 deviate
g. Light Ageing (*) - DIN 30670
by more than 35%
of original value
Cathodic Disbondment mm radius of
h.  @ +65 °C after 30 days disbondment 15 max. ASTM G42
 @ +65 °C after 48 hrs (**) 7 max.
Degree of Cure of Epoxy
i.  Percentage Cure, H % 95 CSA Z 245.20-98
 Tg °C +3 / -2 (***)
Notes:
(*) Test carried out in an independent laboratory of national/international recognition on PE topcoat 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.
5.4 The acceptable combinations of coating material shall be as per Annexure-I.
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 Owner/ Client
considers to be relevant and required for all incoming bare pipes and Owner/ Client 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 as well as in excel format and 8 Nos
Compact Disc (CD). Contractor shall provide one Computer Terminal to Owner/ Client
Representative for monitoring/tracking of the above. The Contractor shall also submit the
material balance details to Owner/ Client 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
Owner/ Client 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.

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Page 10 of 28
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.
e. Plant Organization Chart and availability of manpower including coating specialist
f. Details of utilities/facilities such as water, power, fuel, access roads and
communication etc.
After Owner/ Client has given approval; no change in plant set-up shall be made. However,
unavoidable changes shall be executed only after obtaining written approval from Owner/
Client.
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 Owner/ Client 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. Pipe heating, temperatures and control prior to epoxy application.
d. 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).
e. Application of FBE powder, adhesive and polyethylene, including characteristics,
temperature, line speed, application window, curing time, etc.
f. Quenching and cooling, including time and temperature.
g. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting
formats, including instrument and equipment types, makes and uses, etc
h. Detailed method of repair of coating defects duly classified depending upon nature
and magnitude of defects and repair thereof including coating stripping technique
i. Details of instrument and equipment calibration methods including relevant
standards and examples of calibration certificates.
j. Complete details and inventory of laboratory and equipment for procedure
qualification and regular production
k. Pipe handling and stock piling procedures
l. Sample of recording and reporting formats, including laboratory reports, certificates
and requirement as per clause 6.0 of this specification.
m. Complete details of test certificates for raw materials including test methods and
standards used.
n. Test certificates from PE compound manufacturer for tests for thermal aging, coating
resistivity and aging under exposure to light. These test certificates shall not be older
than three years.
o. Health, Safety and Environment Plans.
p. Storage details of coating materials and chemicals.
q. 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 Owner/ Client. No change in the procedure shall be
made after the Owner/ Client has given approval. However, unavoidable changes shall be
executed only after obtaining written approval from Owner/ Client.
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

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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
Owner/ Client Representative. Out of these pipes, at least one pipe at start and end of PQT
shall be coated partly with epoxy and partly with both epoxy and adhesive layers.
At least 10 (ten) test pipes shall be selected by Owner/ Client Representative for coating
procedure approval tests and shall be subjected to procedure qualification testing as described
hereinafter. Owner/ Client Representative shall witness all tests. Out of 10 (ten) test pipes, 2
(two) pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers
shall be included. Remaining 8 (eight) 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 v/s 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 the
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 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 Owner/ Client
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 shot to grit 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 on the abrasive blast cleaned pipe surface.
7.4.4 Coating Application
The Owner/ Client Representative will check the correctness of each coating application
operation, values of the main parameters of each operation, pre-heating pipe surface
temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy

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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.
7.4.5 Chemical Pre-treatment

7.4.5.1 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.
7.4.5.2 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.
7.5 Qualification of Applied Coating

7.5.1 Tests on pipe coated partly with epoxy and partly with epoxy & adhesive layers
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.

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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.245.20-02, 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.245,20-02, 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 as
per CSA Z.245, 20-02, 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 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 fails 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. One sample for 30 day CD shall be sent to independent approved LAB. The
tests shall comply with the specified requirement.
f. Holiday Inspection

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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. Silicon coated sulphite paper shall be placed between
the epoxy layer and adhesive layer immediately after epoxy application, to ensure
physical separation of epoxy & adhesive as well as to prevent contamination of epoxy
with adhesive layer, at a location from where the epoxy samples are to be removed
for the test. 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:
a. Surface cleanliness, surface roughness measurements and dust control immediately

after second abrasive blast cleaning and salt test.
b. 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 Owner/ Client 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 Owner/ Client, Contractor shall commence
production coating.
7.7 On successful completion of PQT, coating of all test pipes 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 Owner/ Client 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 Owner/ Client, in the event of, but not limited
to, the following:
- Every time there is a change in the previously qualified procedure.

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- 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 Owner/ Client’s opinion the properties are deemed to be suspect
during regular production tests.
7.9 Owner/ Client 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 Owner/
Client's opinion, the results are deemed suspect. Owner/ Client'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 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.
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. 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
short/grit into the pipe.
8.6 All pipes shall be tested for salt contamination after blast cleaning unit. One test shall be
carried out on each pipe. The acceptance criteria shall be 2 g/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. Any pipe having salt
contamination exceeding 2 g/cm² shall be either reblasted or deionised water washed and
then rechecked for salt contamination. In case salt level less than 2 g/cm² is consistently
achieved, the frequency of salt contamination testing may be relaxed to at least one pipe per
hour at the sole discretion of the Owner/ Client Representative.

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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 cleaned pipe shall
conform to near white metal finish to SA 2 ½ of ISO 8501-1. Surface of pipe after abrasive
blast cleaning shall have an anchor pattern of 50 to 80 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 2½), 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. Tape used for assessment of
degree of dust shall comply IEC 454-2. Pressure shall be exerted on the applied tape using a 4
kg roller, prior to peeling-off to assess the degree of dust.
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 Owner/ Client
Representative and on permission from Owner/ Client 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 Owner/ Client 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 that 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.
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 Owner/ Client'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.

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Owner/ Client'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 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 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. The dew point shall be 3°C less than the pipe temp. & RH should be less
than 85%.
8.14 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 Owner/ Client, 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 °C or 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.

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9.1.4 Temperature of the pipe surface shall be continuously monitored & recorded by using suitable
instruments such as infrared sensors, contact thermometers, thermocouples etc. The recording
method shall allow to correlate each linepipe. 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 Owner/ Client Representative’s instruction.
9.1.6 Contractor shall ensure that pipe surface emissivity variations are minimised 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 0.200 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 0.250
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 Thickness (mm)

Pipe Size
(Specified Outside Diameter)
Reinforced Type (v)
Up to 30” (762 mm) 3.2
From 32” (813.0 mm) and above 3.7
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 Owner/ Client 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.

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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 fluidised bed, epoxy spray
system and epoxy recycling system shall be at least (–) 40°C and this shall be 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 able
capable of raising 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 Owner/ Client 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.
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 Owner/ Client.
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 at the below mentioned distance from pipe ends:
S.NO. Pipeline Size Coating cut back length

1 36” NB 150 mm +20 mm / (-)0 mm
2 8” NB to 30” NB 110 mm +10 mm / (-)0 mm
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°.

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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 Owner/ Client at Contractor's expense.
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.
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 focussed 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.
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 Owner/ Client 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.

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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.
e. Holidays, which are lesser in size than those mentioned in (d) above, shall be repaired
in accordance with a 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 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 Owner/ Client
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 as per approved
QAP.
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.

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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 as per approved QAP.
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

a. 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. Silicon coated sulphite paper shall be placed between the epoxy layer and
adhesive layer immediately after epoxy application, to ensure physical separation of
epoxy & adhesive as well as to prevent contamination of epoxy with adhesive layer,
at a location from where the epoxy samples are to be removed for the test. 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
the specified requirements.
b. Frequency of this test shall be once per shift. Pipe shall be selected randomly by
Owner/ Client Representative during the middle of a shift. Suitable
provisions/arrangements as per the instructions of Owner/ Client Representative shall
be made by the Contractor for this purpose
c. 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.

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10.10 Epoxy Layer Adhesion Test
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 30°/150°. 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
back 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 Disbondment 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. Owner/
Client 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 Owner/ Client reserves 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 despatch 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
Owner/ Client's representative. Inspection and tests performed or witnessed by Owner/
Client'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 Owner/ Client for approval. Contractor
shall recommence the production only after getting the written permission from Owner/
Client.
Under no circumstances any action or omission of the Owner/ Client's Representative shall
relieve the Contractor of his responsibility for material and quality of coating produced. No

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pipes shall be transported from the coating plant unless authorised by Owner/ Client in
writing.
10.16 Cyclic test one cyclic test shall be conducted after completion of coating followed by strip test
of coating to locate any failure on disbondment. for cyclic test the pipe shall be pressurized to
1.5 times of design pressure and then dropped to 5% of design pressure and again re-
pressurized to 1.5 times design pressure, continuously for about 100 cycles then checked for
coating disbondment by stripping the pipe coating.
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 Owner/ Client 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 Owner/ Client. All pipes shall
be checked for bevel damages, weld seam height, dents, gouges, corrosion and other
damages. Owner/ Client 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
rebevelled 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 Owner/ Client. Any reduction in length shall be 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 Owner/ Client a procedure/calculation generally in
compliance with API RP-5L1 for stacking of pipes of individual sizes, which shall be
approved by Owner/ Client 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 Owner/ Client 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 remains 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.
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
Owner/ Client approval in this regard. Each pipe section shall be separated by means of

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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 flat bed type
lorry/ Trailer. Total width of the supports shall be at least 5% of the pipe length and min. 4
nos. 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 Owner/ Client for approval prior to undertaking
such transportation works. In addition 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 Owner/ Client, its methods and materials proposed to be used for
executing a coating repair and shall receive approval from Owner/ Client 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 pipe leaving coating plant, shall have sound external coating with no holiday or porosity
on 100% of the surface.

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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 cm2 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 140 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 120 mm.
Not withstanding the above, if any 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:
- 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 Owner/ Client 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 Owner/ Client 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 Owner/ Client.

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13.0 MARKING
Contractor shall place marking on the inside and out side coating of opposite surface ends
along with barcode or RF ID as per specification at one end of the coated pipe, and marking
shall indicate, but not limited to the following information:
a. Pipe number, Heat number

b. Pipe diameter, material grade, length & wall thickness
c. Coated pipe number
d. Colour band
e. Any other information considered relevant by Owner/ Client.
f. Pipe Manufacturer Name
g Inspection Mark/Punch
Contractor shall obtain prior approval on marking procedure to be adopted from the Owner/
Client.
14.0 QUALITY ASSURANCE
14.1 The Contractor shall have established within his organisation 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 organisation 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 Owner/
Client 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 organisation.
14.5 The Contractor shall, prior to the commencement of work, prepare and issue a Quality Plan
for all of the activities required satisfying 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 Owner/ Client Representatives who will witness and accept the inspection, testing and
associated work required by this specification.
14.7 The coating pipe mill shall have internal tracking system for their pipe traceability-inline
production to reduce manual introversion. SAP base system is preferred.

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ANNEXURE-I
LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS
The following combinations of coating materials are considered acceptable. In case any of the
combinations listed below are offered, details regarding properties of the offered materials need not
be furnished with bid. However, In the event of award of contract, Contractor shall furnish the
combination(s) proposed and re-confirmation of compatibility of the proposed combination (s) from
the raw materials Manufacturers.
Epoxy Powder Adhesive PE Compound

(Manufacturer) (Manufacturer) (Manufacturer)
CORRO-COAT EP-F 2001 FUSABOND 158D SCLAIR 35 BP HDPE

(JOTUN) (DUPONT) (NOVACOR)
CORRO-COAT EP-F 2002HW

(JOTUN) LUCALEN G3710E LUPOLEN 4552 D SW 00413
or (LYONDELLBASELL) (LYONDELLBASELL)
SCOTCHKOTE 226N
(3M)
PE 50-6109
(BASF)
or
CORRO-COAT EP-F 2001/ ME 0420 HE 3450
2002HW/1003HW (BOREALIS) (BOREALIS / BOROUGE)
(JOTUN)
or
SCOTCHKOTE 226N
(3M)
CORRO-COAT EP-F 2001 LE – 149 V ET 509 B

(JOTUN) (HYUNDAI ENGINEERING (HYUNDAI ENGINEERING
PLASTICS) PLASTICS)
Although the above combinations would be acceptable to Company, the responsibility of suitability
for application, performance and compliance to the coating system requirements shall unconditionally
lie with the Contractor.

SPECIFICATION FOR SPECIFICATION NO.
INTELLIGENT PIGGING FOR A286-000-06-42-IP-12-02
MEHSANA-BATHINDA PIPELINE Rev. 2
(SMMS) Page 1 of 20

TECHNICAL SPECIFICATION
FOR
INTELLIGENT PIGGING
PROJECT : MEHSANA – BATHINDA PIPELINE

OWNER : GSPL INDIA GASNET LIMITED
PMC : ENGINEERS INDIA LIMITED
JOB NO. : A286
CLIENT’S COMMENTS INCORPORATED

2 12.09.12 S. Das R. Chaudhury R. Chaudhury
& REISSUED FOR BIDS
CLIENT’S COMMENTS INCORPORATED
1 03.09.12 S. Das R. Chaudhury R. Chaudhury
& ISSUED FOR BIDS
0 22.08.12 ISSUED FOR BIDS S. Das R. Chaudhury R. Chaudhury
Date Purpose
No by by by
(SMMS) Page 2 of 20
SCOPE OF WORK AND TECHNICAL SPECIFICATIONS
CONTENTS
PART I
1.0 INTRODUCTION AND PROJECT SITE
2.0 OBJECTIVE
3.0 SCOPE OF WORK
4.0 CONTINGENCY WORKS
5.0 ABNORMAL SITUATIONS
PART II
1.0 INTENT
2.0 TECHNIQUE FOR INTELLIGENT PIGGING
3.0 VELOCITY OF DIFFERENT PIGS
4.0 CLEANING PIG AND MAGNETIC CLEANING PIG RUNS
5.0 GAUGING AND ELECTRONIC CALIPER PIG
6.0 INTELLIGENT PIG RUNS
7.0 DEFECT SIGNIFICANCE
8.0 PRE-CALIBRATION OF INSPECTION TOOL.
(SMMS) Page 3 of 20
SCOPE OF WORK AND TECHNICAL SPECIFICATIONS
PART-I: SCOPE OF WORK
1.0 INTRODUCTION AND PROJECT SITE
GSPL India Gasnet Limited (GIGL) is implementing cross-country pipeline running

from Mehsana to Bathinda including several spur lines.
2.0 OBJECTIVE
The objective of the present pigging programme including in-line inspection is to

generate baseline data for the internally coated pipelines.
3.0 SCOPE OF WORK
The scope of work under this tender include in line inspection by running high
resolution intelligent pig based on magnetic flux leakage technique to detect and
quantify internal/external corrosion/mechanical defects and other anomalies preceded
by proving, cleaning, magnetic cleaning, gauging, caliper (Geometry) pig run and XYZ
mapping concurrently with CDP run. All facilities/services which the EPC
CONTRACTOR feels necessary to fulfill the WORK shall have to be arranged by him
at no extra cost and time to the OWNER.
3.1 DETAILED SCOPE OF WORK
3.1.1 ACTIVITIES
(a) Mobilization of all equipment e.g. cleaning pigs, magnetic cleaning pigs, gauging pig,
caliper pigs, intelligent pig (MFL – CDP), XYZ mapping capable ILI tool, pig locating
and pig tracking devices, pig tracking personnel, marker devices, installation of magnet
markers (Physical installation of Marker by doing necessary excavation/backfilling etc
shall be under taken by EPC contractor), spares, consumables, communication,
transportation, pig handling/lifting equipment of required capacity and personnel from
the country of import to the WORK SITE custom. The quantities to be mobilized for
different equipment (different types of pigs, pig tracking device, Marker device)
accessories, spares, and consumables need to be carefully evaluated by the EPC
contractor taking in to the consideration that on line inspection of various segments
should be carried out without any constraint. EPC CONTRACTOR is to mobilize all
types of required pigs, accessories, spares, pig locating and tracking devices, in
adequate number for completion of entire works within the contract price without
depending turnaround time of bringing the pig received from previous run from receive
station to launch station. As such no turn around period shall be allowed due to
operational constraints.
MINIMUM RESOURCES TO BE MOBILIZED BEFORE COMMENCING THE JOB
The various pigs, tracking devices/ transmitters/ consumables should be assessed

properly & arranged as per the actual site requirement & in no way should be limited to
these minimum resources numbers. Any shortage in these resources will be
considered as non-adherence to the contract conditions. For each line, at least 1
Cleaning, 1 Magnetic Cleaning Pig (or a combo cleaning/Magnetic cleaning Pig) along
with 2 sets of Pig tracking transmitter and Receiver shall be ‘new’ ones and after their
(SMMS) Page 4 of 20
use in this Contract shall be Handed over to GIGL along with unused consumable viz.
Sealing Discs, Guiding Discs and Sealing cups and shall become GIGL property.
The minimum but not limited to the following resources are envisaged to be mobilized
by the EPC contractor for completion of job. However, EPC contractor is expected to
make their own assessment of actual resources required for them and mobilize
accordingly. The following is only a guideline and should in no way be considered as
constraint for timely and satisfactory completion of job.
Pig tracking devices and transmitters for pig tracking
EPC contractor shall mobilize adequate numbers of transmitters, personnel for

tracking of pig for each segment of pipelines under scope of work without waiting for
turnaround time. It is proposed that pig tracking would be done in a discrete manner
generally at 5 to 10 KM intervals on each pipeline segment at pre-selected locations
for MBBL. EPC contractor should be in position to mobilize additional tracking devices
if required depending on terrain, accessibility to tracking locations etc.
Further the EPC contractor shall mobilize adequate no of personnel to track each pig
during its movement in the pipeline.
CONSUMABLES
Consumable items shall be depending on the line condition, construction features and
design details of different pigs and EPC contractors own experience in similar projects
of running his tool. However, EPC contractor must ensure that in no case the site
activities should suffer due to shortage of spares. Consumables will include following
 Connecting cables and clips, cords etc. as required by the job shall be brought in two
sets.
 Bolts & Nuts. Fasteners, pins, spacers and other similar mechanical consumables
should be brought 200% spares.
 N2 Bottles as required during assembly of electronics shall be brought.
 Marker magnets for placement at 2 KM interval. (Magnets not to be retrieved back.)
SPARE PARTS FOR EACH GROUP OF PIPELINES UNDER SCOPE OF WORK
 20% of primary and secondary sensor assembly for each size of CDP.
 15% of cables cords, for electronic and sensors for each group of pipeline.
 2 sets of electronic assembly including electronic cords tape recorder and cassette
and other electronic components, which can be replaced at the site by the field
personnel.
 Set of all type of Batteries with minimum 200% backup, for the overall project
requirement
 Wear plate /glide shoes of Magnet assembly in Corrosion detection pig with minimum
50% backup.
 One spare set of Odometer wheel assembly including cables for each size of
pipe/EGP/IP Tool.
 One set of backup software required for calibration of EGP/CDP.
 200 % spare battery backup for pig tracking devices and transmitters and each Pig
run shall use only new set of batteries especially the Pig transmitter batteries.. Pig
tracking transmitter battery shall have backup time of not less than 150hrs – to take
care of the eventuality of stuck pick situations.
(SMMS) Page 5 of 20
TOOLS AND TACKLES
 At least 2 set of tools and tackles required for servicing of each size of cleaning
Brush, Cleaning Magnet EGP/CDP and Gauge Pigs.
 Two sets of pusher rod for pushing the pig inside the barrel.
 Two sets of lifting sling suitable for each type of pig.
 2 sets of “COME-ALONG” tackle for with about 5 meter of rope for pulling the tool
out of receiver barrel.
 Forklift or similar lifting and local transportation lifting/handling equipment of
adequate capacity at launcher and receiver station shall have to be arranged by
the EPC contractor.
MANPOWER
A team of at least 2 qualified personnel for working in each segment shall be deployed.
All facilities /services which the EPC CONTRACTOR feels necessary to fulfill the
WORK shall have to be arranged by him at no extra cost and time to the
COMPANY/EPC contractor.
PERMANENT MAGNET MARKERS

EPC contractor to supply adequate numbers of permanent magnet markers on the
pipeline at 2 (two) Km interval irrespective of permanent pipeline installations. These
permanent magnet markers shall not be retrieved back after completion of inspection
work and shall not be taken back by EPC contractor.
Installation of Permanent Magnet markers on the Pipeline surface – without removing

the 3 layer PE coating shall be done by EPC contractor, as per the Installation
instructions to be provided by EPC contractor. In order to facilitate timely installation of
the Markers, EPC contractor is expected to dispatch them within 2 weeks of placement
of Purchase order and should be delivered at GIGL site within 4 weeks of PO
placement.
Permanent magnet markers thus supplied shall be powerful enough to be able to get
fixed on to the pipeline without the need for removing the 3mm thick 3 layer PE
coating.
PULL THROUGH TEST

EPC contractor is required to conduct Pull through test of Intelligent Pig at his
inspection centre before mobilization of tools to the site. Company/Consultant at his
cost and discretion reserve the right to witness the Pull through test to ascertain
diagnostic capability, reliability etc. of the inspection tools to be deployed at site.
During pull through test the OWNER/Consultant representatives shall be allowed to
share the technical information related to the Corrosion Detection Pig including test
pipe data, tool velocity, magnetization level achieved and metal loss inspection
performance achieved during testing. Pull through test report for each size of
Corrosion Detection pig shall be submitted within seven days of performing the test.
OPERATION MANUAL AND PROCEDURE DOCUMENT

EPC contractor shall submit operation manual for pigs and procedure document for
execution of the field activities for the various pipelines covered under scope of work
before commencing the job for OWNER/CONSULTANT approval.
(SMMS) Page 6 of 20
(b) MODIFICATION OF RECEIVER & LAUNCHER TRAPS, IF REQUIRED, TO SUIT

EPC CONTRACTOR'S TOOL DIMENSIONS – NOT ALLOWED.
EPC contractor to satisfy himself that their pigging requirements can be met by the
existing Pig launcher and receiver. No modification shall be allowed to be
undertaken on these launcher / receiver barrels.
(c) Carrying out adequate number of gauging pig runs in each pipeline segment covered
under SCOPE OF WORK including pig tracking for each segment to assess any
internal restriction in the pipeline and provide detailed daily site report for each run in
the approved format before commencing the subsequent run, to establish ‘GO’ or ‘NO-
GO’ state of the Pipeline for further pig runs required like cleaning, Magnetic cleaning
and MFL-CDP. Only in the situation of ‘NO-GO’ state of the Pipeline as found from the
result of Gauge Pigging, Electronic geometry (Caliper) Pig runs shall be undertaken. If
pipeline condition is in ‘GO’ condition the SOR items for Electronic geometry (Caliper)
Pig runs shall not be operated.
(d) Carrying out adequate number of cleaning pig and magnetic cleaning pig runs by
running suitable cleaning pigs in each pipeline segment covered under SCOPE OF
WORK including pig tracking till such time EPC CONTRACTOR is satisfied with
himself about the degree of cleanliness of pipeline segment and provide detailed daily
site report for each run in the approved format before commencing the subsequent
run.
(e) If need arises, Carrying out one single electronic geometry (caliper) pig runs in each
pipeline segment, as needed covered under SCOPE OF WORK including pig tracking
for each segment decided after findings of gauge pig run and analysis of data of the
caliper survey to detect the nature, extent (in % ID of pipeline) and location of internal
constriction (dent) in the pipeline segment and provide detailed daily site report for
each run in the approved format before commencing the subsequent run. Any further
run requirement, in the absence of valid and full data can be undertaken only by
consent of Owner/Consultant, the cost towards all such additional runs till generation
of valid and physically verifiable data shall be deemed to be included by EPC
contractor in their quoted rates.
The EPC contractor to submit typical data logs for EGP pig run alongwith site report
and demonstrate that the minimum internal bore/maximum constriction detected in the
pipeline do not exceed the limitation of High resolution inspection tool. Detailed
processed EGP logs shall be submitted alongwith the final Work Report.
(f) Carrying out one single intelligent pig runs in each pipeline segment by running high
resolution MFL tool including pig tracking on each segment to generate valid and
physically verifiable data for identification of external and internal corrosion, other
defects/ anomalies, location of girth weld, valves, lateral joints and tees and submit the
detailed daily report indicating the data is generated for the entire length of segment.
The preliminary site report shall be submitted by EPC contractor alongwith the typical
data logs of CDP. Any further run requirement, in the absence of valid and full data
can be undertaken only by consent of Owner/Consultant, the cost towards all such
additional runs till generation of valid and physically verifiable data shall be deemed to
be included by EPC contractor in their quoted rates.
For internally coated pipes, adequate care shall be taken by using soft cups so that no
damage takes place to the internal coating of the pipe. EPC contractor to ensure that
his magnetic cleaning, gauge pig and EGP tool shall be so equipped that the tools will
not damage internal coating of the lines.
(SMMS) Page 7 of 20
(g) XYZ mapping data acquisition shall be done concurrently with MFL - CDP run only.
Any further run requirement, in the absence of valid and full XYZ mapping data can be
undertaken only by consent of Owner/Consultant, the cost towards all such additional
runs till generation of valid and physically verifiable XYZ mapping data shall be
included by EPC contractor in their quoted rates of MFL-CDP runs. EPC contractor is
required to get valid interpretable and verifiable data for pipeline. XYZ mapping
measurement shall cover the entire 360 degree of internal pipe circumference using
properly oriented and by sufficient quantity of sensors.
(h) DEFECT VERIFICATION
At the discretion of COMPANY/CONSULTANT Identify at least a set of 12 (6+6) twelve

verification dig sites, for each segment, for EGP run as well as MFL –CDP run jointly
with EIL and GIGL from the recorded data and provide EIL/GIGL with their distance
from the nearest pipeline feature or reference marker to facilitate location of defect in
the field. Verification shall be done for every segment within four (4) weeks. In case,
verifiable defects are less than 6, then all defects shall be verified by dig verification.
The defects which are greater than 1t x 1t (t=wall thickness) shall only be offered for
verification.
In case there is a mismatch in the reported defects and that measured at site during
verification then the EPC contractor shall depute his representative to observe
verification by Non Destructive testing at verification sites for proving that field log
detected anomalies conform to wall thickness loss and sizing, including linear and
circumferential positions and defect sizing within the limits of tolerance as per provision
of Bid Document Section Technical Specifications.
In case the verifiable defects are not found on any of the pipeline segments the
permanent features such as valves, bends, tees, external weld metal (copper)
depositions (such as for Cathodic protection cable terminations) or any other feature
on the pipeline including the marker magnet locations should match in the field with the
reported locations. Pipe tally should match with earlier survey data upto 95% of the
Pipes.
(i) Demobilisation of all equipment, tools and personnel on completion of field activities
for all segments.
(i) Final data analysis of the Intelligent Pig inspection record at the EPC contractor’s data
analysis centre. COMPANY shall associate its representative(s) and representative(s)
of its CONSULTANT in the data analysis WORK at the EPC contractor’s data analysis
centre at their own expenditure for the first segment and the subsequent segment at
their discretion. The analysis shall consist of following as a minimum.
 Identification of all pipeline permanent features e. g. girth welds, valves, tees, sleeves,
welds, external weld metal depositions (such as for Cathodic protection cable
terminations)etc.
 Potentially hazardous defects/ mechanical defects including circumferential gouging,

axial gouging etc. affecting structural integrity of the pipeline.
 Three-dimensional defect sizing (Depth, length & circumferential width) for all
"significant defects"(Defects  10% metal loss), grading of defects, differentiation
(SMMS) Page 8 of 20
between external and internal defects and also differentiation between corrosion
defects and mechanical defects.
 Report on interactive corrosion due to clustering of pits.
 Preparation of final processed inspection logs and preparation of complete WORK

report giving interpretation of the inspection logs and giving defect sizing of corrosion
defects and their gradation.
 Providing all the raw and processed data along with the software package for enabling
COMPANY/CONSULTANT to study the data, if required. The software should be user
friendly.
(k) FINAL WORK REPORT
The final work report shall be for each segment including proving, cleaning, magnetic
cleaning, gauging, caliper and corrosion detection pig runs details with operational and
functional parameters, daily detailed site report of each run with observations,
individual feature report, severity analysis, velocity plot of Intelligent pig, defect
distribution along the length of segment etc as detailed out at para 7.10 of part II. The
work report shall be submitted in hard copy (4 sets) and soft copy (2 sets).
3.2.2 TRANSPORTATION
The EPC contractor shall arrange transportation of his tools, tackles, equipment,
expatriates from country of origin to work site and back. The EPC contractor shall hire
local transport for transportation of his equipment and personnel from launcher station
to receiving station and back as required. This shall involve as a minimum 2 passenger
vehicles suitable for use on unsurfaced roads/Motarable tracks and 1 truck for
transporting Pigging material in one segment.
3.2.3 INSTALLATION OF MAGNET MARKERS BY EPC CONTRACTOR (MAGNET

MARKERS TO BE SUPPLIED BY EPC CONTRACTOR)
It will be the responsibility of the EPC contractor to supply adequate no of magnet

markers so that there is one marker at every 2-KM interval. The magnetic strength of
these magnets shall be adequate so that they properly reflected on the IP tool logs for
the ease of over the land measurement to spot out the defects identified for defect
verification.
Installation of Permanent Magnet markers on the Pipeline surface – without removing

the 3 layer PE coating shall be done by EPC contractor, as per the Installation
instructions to be provided by EPC contractor. In order to facilitate timely instatllation of
the Markers, EPC contractor is expected to dispatch them within 2 weeks of placement
of Purchase order and should be delivered at GIGL site within 4 weeks of PO
placement.
4.0 CONTINGENCY WORKS
EPC CONTRACTOR to write down in his offer all foreseeable abnormal circumstances
during the execution of the project for enabling the COMPANY/CONSULTANT to take
(SMMS) Page 9 of 20
appropriate measures in time, to be prepared should such a condition arise during the
implementation of the project.
In the event of pig getting stuck in the pipeline during pigging activity EPC
CONTRACTOR shall assist the COMPANY in the retrieval of the tool. This assistance
will be limited to his providing advice on the operation methodology to be adopted for
salvaging the tool and in putting back the pipeline in normal operating condition. Also
refer clause no. 5.3 of this section for details.
5.0 ABNORMAL SITUATIONS
The objective of this section is to write down foreseeable abnormal circumstances for
taking appropriate measures, when such a condition arises during implementation of
Project.
The COMPANY has foreseen the following abnormal conditions. However, if the
CONTRACTOR foresees any other abnormal condition, he is free to make a mention of
the same in his technical BID offer:
5.1 MAJOR MODIFICATION IN PIPELINE
During execution of pigging for a particular pipeline segment defined in the `Scope of
WORK' of this document, if it is found that it is not feasible to proceed with subsequent
stage of pigging in that particular segment, unless major rectification of certain areas of
pipeline are completed, then, the COMPANY, CONSULTANT and the CONTRACTOR
shall hold discussion and come to a mutual agreement about revised pigging
programme for that segment of pipeline. As this shall be decided in Gauge Pigging /EGP
itself, and company/Consultant anticipate that MFL-CDP pig shall not be mobilized to
site at this point of time, Company/Consultant expect EPC contractor to demobilize and
mobilize (after getting written Company’s intimation that Major modification required to
pipeline has been completed) without cost implication, while any cost implications are
deemed to be included in the quoted prices. Needed Time extension to the contract shall
be given by Company.
5.2 TOOL FAILURE
EPC CONTRACTOR is required to get valid interpretable and verifiable data for each
segment of pipeline.
In case EPC CONTRACTOR is not able to perform fully to the satisfaction of

CONSULTANT/COMPANY and generate valid data for the each pipeline segment
covered under SCOPE OF WORK during the live runs of electronic geometry pig and
live intelligent pig, the payment shall be made as per provision of clause of SCC (Terms
of Payment).
In case EPC CONTRACTOR'S equipment fails to perform electronic geometry

pre-inspection and/or intelligent pigging inspection to generate valid data for any of the
segment, EPC CONTRACTOR will make extra runs of Pigs to get valid and physically
verifiable data. The schedule completion date shall remain unaltered under such
circumstances.
Due recognisation of all Girth welds in the pipeline segment with 90% of POD, Valves as
per the pipe book /Pipe tally of COMPANY shall be deemed as reference for checking
that Live runs EGP and Live MFL-CDP has produced valid interpretable and verifiable
data for each segment of the pipeline.
(SMMS) Page 10 of 20
Further all sensors should be functional for the entire length of the EGP run / MFL –
CDP run.
Failure in above cases shall be deemed as possible extra run requirement in that pipe
segment, Company/Consultant’s engineer’s decision shall be final with regard to
necessity of additional EGP run and/or MFL-CDP after due verification of EGP / MFL -
CDP data.
Data loss due to loss of sensor functioning shall not occurred for any length of Buried
section of the pipeline – however small that buried pipe section may be. Such Data loss
shall require re-run of EGP tool and /or MFL-CDP tool as the case may be, by EPC
contractor at no extra cost and time to GIGL.
Any redundancy in sensors that shall enable acquiring valid, interpretable and physically
verifiable data in EGP / MFL-CDP shall be informed to Company/Consultant at technical
bid stage itself. For example EPC contractor’s tool deploys two odometers and loss of
one odometer shall not in any way affect the data to be acquired. Such sensor
redundancy report shall be given as part of Technical bid itself. Same shall be taken into
cognizance by COMPANY/CONSULTANT in deciding sensor loss as having affected the
successful tool run or not.
The EPC CONTRACTOR shall decide the replacement/repair/modification of the

CONSTRUCTIONAL PLANT AND EQUIPMENT / PIGS / INSPECTION TOOLS. In
case the EPC CONTRACTOR decides to take the CONSTRUCTIONAL PLANT AND
EQUIPMENT / PIGS / INSPECTION TOOLS or any of its component for
repair/modification from the site, then he shall be permitted to do so provided he
furnishes an additional bank guarantee for an amount equal to payments made to him by
the COMPANY for the respective group of pipelines up to this stage. The Bank
Guarantee so furnished shall be valid for a period of four months. The EPC
CONTRACTOR shall be responsible for all costs including but not limited to transport
from/to India, re-export duty/ Custom duty for Import/re-Import of the replaced/modified/
repaired CONSTRUCTIONAL PLANT AND EQUIPMENT / PIGS / INSPECTION TOOLS
without any additional payment from the COMPANY on this account. In case EPC
CONTRACTOR fails to re-mobilize for completion of the WORKS, the above additional
bank guarantee shall be liable to be invoked by the COMPANY without any prejudice to
other remedies and provisions of the CONTRACT.
5.3 STUCK-UP TOOL
For the entire duration of this contract pigging activities, it shall be the responsibility of
the successful pigging EPC contractor to locate the stuck pig within an accuracy of +/-
5 m.
If EPC contractor so requests, as part of the technical bid, GIGL/EPC contractor shall
allow running of Gauge plate Pig with Gauge plate of 95% of minimum ID of pipeline,
to be supplied by EPC contractor, at the onset of this contract activities. If such Gauge
plate pig gets stuck, EPC contractor shall remove the same entirely at their cost and
time, after trying alternate methods like pressure surges etc. Giving location of such
stuck Gauge plate pig within +/- 5 m shall be in EPC contractor’s scope only.
Upon such successful gauge plate pig run – which comes out of pipeline either with
slight damage or without damage, the rest of the pigging activities and ensuring none
of the Cleaning pig, Magnetic cleaning pig, Electronic Geometry pigs, MFL-CDP pigs
PART II TECHNICAL SPECIFICATIONS
1.0 INTENT
The intent of the specification is to set forth the requirements of the on-line inspection
of the pipelines to help EPC CONTRACTOR quote his unit rate PRICE in the
schedule of rates. This requirement is not intended to be all inclusive and use of
guidelines setforth does not relieve the EPC CONTRACTOR to his responsibility to
carry out all activities successfully as defined in Scope of WORK and to obtain valid,
interpretable and physically verifiable data from the intelligent pig runs about the
condition of the pipeline.
2.0 TECHNIQUES FOR INTELLIGENT PIGGING
The Corrosion Detection tool used for On line Inspection for pipeline segments
covered under "Scope of Work” in response to this bid, should be High resolution
inspection tool based on Magnetic Flux leakage Technology (push type).
3.0 VELOCITY OF DIFFERENT PIGS AND MINIMUM DIAMETER NEGOTIABILITY
EPC CONTRACTOR shall be required to maintain the velocities of different pigs in

such a manner that normal flow through a particular segment while a particular pig is
traveling is not required to be altered.
The operating flow rates for different segments are given in this document.
The Minimum Diameter negotiability shall be as under:
Gauge plate Pigs, Cleaning and Magnetic Cleaning Pigs: 85% of Minimum ID of Pipe
segments
Electronic Geometry Pigs: 85% of Minimum ID of Pipe segments
MFL-CDP / XYZ mapping: 90% of Minimum ID of Pipe Segments
4.0 CLEANING PIG AND MAGNETIC CLEANING PIG RUNS
Prior to launching of corrosion detection pigs, EPC CONTRACTOR shall complete all
activities required to establish piggability and adequate cleanliness of pipeline to the
satisfaction of the EPC CONTRACTOR and to verify the internal geometry of the
pipeline with relation to ovality, dent etc. and to ensure that internal bore restriction at
any location does not exceed the limitation of proposed tools to be used
subsequently. EPC CONTRACTOR shall decide the number of cleaning runs and the
choice of the cleaning pig for each cleaning run as suitable for the purpose to obtain
internal condition adequately clean so as to obtain valid and interpretable inspection
data from the intelligent pig and to safeguard caliper and intelligent pig against
damage due to debris.
The cleaning pigs for successive cleaning pig runs shall be selected by the EPC
CONTRACTOR in such a manner that effective cleaning is achieved with minimum
number of runs and then the same should not get lodged into the pipeline.
The detailed specifications of cleaning pigs and magnetic cleaning pigs shall be
furnished in the offer. EPC contractor to furnish minimum % of ID /constriction that his
cleaning pigs is capable to pass without any damage to tool and pipeline.
5.0 GAUGING AND ELECTRONIC GEOMETRY (CALIPER) PIG RUNS
5.1 GAUGING PIG:
Following the cleaning pig runs, EPC CONTRACTOR shall run a gauging pig with the
gauging plate made of Aluminium and its diameter should be 95% of minimum
pipeline internal diameter. EPC CONTRACTOR' s cleaning and gauging pig
assemblies should be able to pass over or negotiate lateral tees or bends of sizes or
radii. The detailed specifications of gauging pig shall be furnished in the offer with
specific reference to the minimum % of ID that the gauge pig can pass without
damage to pig and pipeline.
5.2 ELECTRONIC GEOMETRY (CALIPER) PIG:
The electronic geometry (caliper) pig should be capable of recording the entire length
of each segment i. e. from launcher to receiver in one single run and therefore its
electronic recorder system should have requisite data storage capacity. Battery life
therefore should be adequate to commensurate with the run time required to travel
the pipe length of each segment and the drive cups should have requisite resistance
to wear and tear to maintain effective seal throughout the entire run time.
The measurement shall cover the entire 360o of internal pipe wall circumference using
properly oriented and sufficient quantity of sensors. The tool should be capable to
identify and locate the following features as a minimum.
 Individual Girth weld

 Dent, ovality, buckles, or any other out of roundness, change in pipeline I.D.
and difference of thickness.
 Bend with bend radius and degree of bend.
 Valves or any partially closed valves.
EPC CONTRACTOR to supplement the following information in his BID.
a) Accuracy of locating indication/I.D.Reduction w.r.t. to circumference (in degrees).
b) Accuracy of locating indication/I.D. Reduction w.r.t. to axial length (Meters).
c) Minimum % of Nominal pipeline I.D./constriction that tool can pass (% ID)
d) Minimum deformation level Reported (as % of I.D.)
e) Accuracy of Measurement (% of I.D.)
f) Bend radius tool able to negotiate
6.0 INTELLIGENT PIG RUNS
Upon completion of all preceding activities (cleaning, magnetic cleaning, gauging,

caliper runs) and based on their results EPC CONTRACTOR shall intimate about his
readiness for running the high-resolution corrosion detection pig.
COMPANY/CONSULTANT shall indicate the exact time of launching the corrosion
detection pig in consultation with EPC CONTRACTOR.
Marker devices should be placed at approximately 1-KM interval in each segment

prior to running of Intelligent Pig. Permanent magnet marker shall be deployed for this
purpose and shall not be retrieved back
The intelligent pig proposed by the EPC CONTRACTOR should be capable of

identifying the following anomalies keeping in view the defect significance detailed out
at para 7.0 below:
 General corrosion
 Pitting corrosion
 Circumferential gouging
 Axial gouging
 Location of girth welds, valves, lateral joints
 Circumferential cracks
 Proximity of any ferrous object to pipeline.
 Manufacturing defects
7.0 DEFECT SIGNIFICANCE
7.1 The following information/performance is expected out from the Geometry

survey.
The Electronic Geometry Pig should detect a minimum of 2% change in internal

diameter and accuracy in detection of length of defects should be 0.5%.
DETECTION CAPABILITY AND SIZING ACCURACY
The tool should have minimum capabilities as under.
7.1.1 Minimum detection level for dent: 2% of ID
Sizing Accuracy for dent: +0% of ID, -25%of measured value or - 1% of ID
7.1.2 Minimum detection level for Ovality: 5% of ID
Sizing Accuracy for Ovality: +/- 2% of ID
7.1.3 Location Accuracy Axial: 0.1% from Permanent Features (or ±1.0 M from Marker)
Within pipe +/- 20 cm
7.1.4 Circumferential location accuracy: +/- 10 degree
7.1.5 The tool should be capable of negotiating minimum 3D bend and 15%reduction in Pipe
ID.
7.2 The classification of metal loss defects used for specifying the detection and sizing
accuracy of Corrosion Detection pig in given in Fig.1.
L 2 37.9939
L4
9
CIRCUMFERENTIAL
CIRCUMFERENTIAL SLOTTING
8
GROOVING
DEFECT WIDTH (A)
7
6
W1
5
L3
GENERAL CORROSION
4 W3
3
L1 2 L2
PITTING
AXIAL GROOVING W2
1
PIN HOLE AXIAL SLOTTING
0 1 2 3 4 5 6 7 8 9
DEFECT LENGTH (A)

L1,L2,L3,L4
IF t >10mm THEN A=PROJECTED AXIAL LENGTH
t mm (WALL THICKNESS)
IF t<10mm THEN A= 10 mm
W1, W2, W3 PROJECTED CIRCUMFERENTIAL WIDTH
FIG.1 CLASSIFICATION OF METAL LOSS DEFECTS
The following information/performance is expected out of the intelligent pig

inspection:
7.2.1 The external or internal metal loss/mechanical defects should be identified,

discriminated, sized (L x B x D) and suitably reported in a mutually agreed manner.
7.2.2 Inspection of entire length of each segment to be completed in one single run.
7.2.3 To check the effect of inter-active corrosion if a cluster of pits is identified close to
each other, values of L1, L2, L3, L4…and W1, W2, W3…. Should be reported (refer
sketch at Annexure II) and the location of each pit cluster is to be identified with
reference to permanent pipeline feature.
7.2.4 Any metal loss in the heat-affected zone of the weld should be specifically highlighted
in the report but may not be sized.
7.2.5 MAXIMUM RUN LENGTH OF LIVE TOOL
The EPC CONTRACTOR must specify in his offer the maximum length which can be
inspected in one single continuous run by the tool proposed by him. It is required to
complete the entire run length of each segment of MBBL pipeline in a single run.
7.2. 6 ACCURACY OF DEFECTS
The best accuracy offered and guaranteed by the EPC CONTRACTOR for each
category of defect should be clearly spelt out. The EPC CONTRACTOR must define
the "pitting corrosion", general corrosion and the accuracy offered by him in each
case for a) depth of corrosion b) axial and circumferential location of corrosion and c)
length of corrosion.
CONFIDENCE LEVEL AND PROBABILITY OF DETECTION.
A confidence level of 80% is acceptable in defect sizing accuracy (i. e. guaranteed

accuracy is acceptable for equal to or more than 80% metal loss features reported)
with 90% Probability of Detection (POD).
The intelligent pig should have as a minimum, the following capabilities with 80%
confidence level and 90% probability of detection (POD).
DETECTION CAPABILITY AND SIZING ACCURACY
IDENTIFICATION/CHARACT MINIMUM SIZING ACCURACY

ERISATION DEFECT DETECTION AT 80% CONFIDENCE LEVEL
CAPABILITY
OF DEPTH AT DEPTH WIDTH LENGTH
90% POD
GENERA L CORROSION 0.10t ±0.1t ±10MM ±10 MM
( [W  3A] AND [L  3A] )
PITTING CORROSION 0.15t ±t OR

±0.1t ±10MM ±t OR ±10
{([1AW 6A] WHICH MM
EVER IS
AND MORE WHICH
[1A  L  6A] EVER IS
MORE
AND
[0.5  L/W  2] )
AND NOT
( [W  3A] AND [L  3A] ) }
AXIAL GROOVING 0.15t ±0.15t ±20MM ±20 MM
[1AW 3A]
AND [L/W  2]
CIRCUMFERENTIAL ±0.1t ±10MM ±10 MM

0.1t
GROOVING
[1A L  3A]
AND [L/W  0. 5]
IF t  10 mm THEN A = 10 mm
IF t  10 mm THEN A = t
L: Axial length of the defect
W: Width of the defect.
LOCATIONAL ACCURACY
A AXIAL
WITHIN PIPE ±0.20 M

FROM MARKER ±1.0 M
B CIRCUMFERENTIAL ±10 DEGREE
8.0 PIG TRACKING
The movement of any type of pig put into the line during pre-inspection or intelligent
pigging shall be required to be monitor along the pipeline length from launcher to
receiver trap. The EPC CONTRACTOR shall detail out the complete methodology of
pig tracking proposed to be deployed by him including complete technical details of the
equipment and device proposed to be used for this purpose.
It is proposed that pig tracking would be done in a discrete manner generally at 5 to 10

KM intervals on each pipeline segment at pre-selected locations for MBBL. The exact
KM chainage of these locations shall be decided at site in consultation with the EPC
CONTRACTOR and CONSULTANT/COMPANY.
The EPC contractors must keep a provision for pig tracking using ISOTOPE technique.
This option may be exercised by the owner/company. In case the owner insists on
isotope technique of pig tracking it shall be the responsibility of the 0wner to make
available the radioisotopes for this purpose from the Indian agencies.
9.0 DEFECT VERIFICATION
Please refer to clause 4.1.1 h) and 5.4 of Part I of this document also.
In case there is a mismatch in the reported defects and that measured at site during
verification then the EPC contractor shall depute his representative to observe
verification by Non Destructive testing at verification sites for proving that field log
detected anomalies conform to wall thickness loss and sizing, including linear and
circumferential positions and defect sizing within the limits of tolerance as per provision
of Bid Document Section Technical Specifications.
In case the verifiable defects are not found on any of the pipeline segments the
permanent features such as valves, bends, tees or any other feature on the pipeline
including the marker magnet locations should match in the field with the reported
locations.
10.0 DATA ANALYSIS
CONSULTANT/COMPANY shall participate in the analysis of the recorded data

together with the engineering and other personnel of EPC CONTRACTOR. This
analysis shall be carried out at EPC contractor’s Analysis Centre to achieve the
following objectives:
a) To identify the locations of internal or external defects likely to jeopardize the

normal safety and operation of the pipeline.
b) To arrive at general methodology of repair to be followed.
c) Short-term measures to be taken in view of potentially hazardous defects, if

found in any of the pipelines.
EPC CONTRACTOR shall provide all raw and processed data and his software
package along with his compatible hardware. The software package shall be user
friendly.
EPC contractor shall carry out temporary/permanent repairs for the defect, if any, as
reported in the IP results.
11.0 FINAL WORK REPORT
The EPC CONTRACTOR shall include in his offer the most appropriate reporting
procedure envisaged for the subject pipeline. This will have to be mutually agreed
between the successful EPC CONTRACTOR and CONSULTANT/COMPANY.
The COMPANY HAS PROPRITARY RIGHTS ON THE DATA ACQUIRED AS PART

OF THIS CONTRACT. DATA THUS ACQUIRED AS PART OF THIS CONTRACT
SHALL NOT BE COPIED, DIVULGED OR SHARED TO THIRD PARTIES. THE
DATA AS PART OF PRELIMINARY OR FINAL REPORTING IN ALL ITS FORMS
EITHER SOFTCOPIES OR HARDCOPIES SHALL BE HANDEDOVER TO
COMPANY ONLY.
However, any reporting system shall include but not limited to the following:
- Preliminary site report within three to four days for each pipe segment for each
running of cleaning including magnetic cleaning, gauge, EGP, intelligent pig
runs
- Stating comments/observations of each run, pig condition, operating parameters
and total time required.
- A detailed report in respect of each pipe segment of running each of the

pre-inspection tool such as cleaning pig, caliper pig.
- A detailed report on the geometry survey of each pipeline segment incorporating

the following supplemented with raw/processed data logs.
 List of installations
 List of Significances with
 Feature information
 Feature type
 Feature description
 Feature log Distance
 Feature Clock orientation
 Feature length
 Feature depth ( Change in ID)
 Installation references
 Distance form next Installation
 Installation Distance
 Installation type
- Velocity plot of EGP
- Temperature Plot
- Elevation Plot shall be generated for XYZ mapping data and furnished. An MS-
Excel file also shall be provided
- GIS compatible XYZ mapping information along with GPS co-ordinates of Marker
locations, Valves, Tees, Pipe welds and Features.
- Pipeline Map shall be generated using the XYZ mapped/GIS information and
furnished.
- GPS co-ordinates as obtained for XYZ mapping shall be provided for Pipe welds,
Valves, Tees, ‘bends start Positions’ and ‘bends end positions’
- Survey Log and enlargement areas of special interest
- Detailed report about running of the intelligent pig including but not limited to the
operational and functional details.
- Details describing the type, size, internal/external discrimination and location of

individual metal loss defects. The location and orientation of each defect should
be suitably listed with reference to permanent pipeline features, girth weld no.,
relative and absolute distance and severity of the defect.
- A detailed report in respect of each defect for which sizing has to be done
indicating its length, width, depth, axial and circumferential location suitably
referenced.
- Depth based feature distribution against pipe length of all metal loss features.
- Severity analysis for all metal loss features having metal loss greater than 20%
for all detected features. Such analysis as a minimum shall use assessment
methods as per ASME B31.G and Rstreng-2 (Modified B31.G) and DNV RP-
F101
- Individual evaluation feature report in great detail for 5 nos. significant metal loss
features of each segment.
- Suitable histograms between absolute distance of pipeline and no. of defects.
- Report on inter-active corrosion due to clustering of pits.
- Proximity of any ferrous objects to pipeline
- Velocity and temperature plot of the intelligent pig along the length of the
segment.
- Comparison of data as per XYZ mapping and pipe book
- The format and pro forma of the above report shall be mutually agreed upon
between the EPC CONTRACTOR and CONSULTANT/COMPANY.
- All the data generated by the EPC CONTRACTOR shall be compiled in a floppy
disk and CD having user friendly operation on a Compatible PC along with the
software necessary for review/analysis of data within one month of successful
completion of the activity. This is required to facilitate selection of significant
defects, their chainage and sizing. EPC CONTRACTOR will submit this floppy
disk and CD, as a part of report. EPC contractor to provide three sets of
CD/Floppy consisting all generated data alongwith compatible operating
software.
- Compatabile Software Data viewing shall be provided. Supplied software shall be
as a minimum for 5 PCs (Windows XP O/s) Licenses or 1 Network license with
one concurrent user at any time.
Reporting procedure complying to “Specifications and requirements for intelligent pig

inspection of pipelines, Version 3.2, January 2005 or latest issued by Pipeline
Operator Forum shall be deemed as minimum required under this contract.
12.0 PRE- CALIBRATION OF INSPECTION TOOL( INTELLIGENT PIG)
EPC CONTRACTOR is required to pre-calibrate the inspection tools (Intelligent pig)

perform the pilot/loop test at his inspection Centre before mobilization of these
inspection tools to SITE. COMPANY/CONSULTANT at its discretion reserves the right
to witness and / or to appoint its authorized agency to witness the above pre-
calibration/pilot/loop tests to ascertain the diagnostic capability, mechanical
performance requirements, reliability etc. of the inspection tools to be deployed at
SITE. However, it is clearly and expressly understood by the EPC CONTRACTOR that
such association of the COMPANY/CONSULTANT for witnessing the pre-
calibration/pilot/loop tests shall in no way absolve the responsibility of the EPC
CONTRACTOR either for the performance of the inspection tools or his obligations
under the CONTRACT. COMPANY/CONSULTANT shall bear the expenses of his
representative /authorized agency related to travel, (to and fro) boarding, lodging and
other incidentals during the period of their stay for witnessing above tests of inspection
the above tests of inspection tools at the inspection Centre of the EPC
CONTRACTOR. Pull through test report for each size of Corrosion Detection pig shall
be submitted within seven days of performing the test.
13.0 XYZ Mapping

XYZ mapping shall be carried out to obtain three dimensional geographical pipeline
co-ordinates. The Pig transverse and rotational movements shall be measured using
inertial navigation unit. XYZ mapped information shall be cross referenced to
Differential GPS co-oridnates acquired at regular intervals using GPS enable Pig
tracking devices.
The mapping should result in the form of reporting covering Pipline alignment,
direction and orientation of horizontal and vertical bends w.r.t angle, radius, direction.
Any abnormal deformation and bending strain occurring in any location of the Pipeline
shall be reported. GPS coordinates as obtained for XYZ mapping shall be provided
for Pipe welds, Valves, Tees, ‘bends start Positions’ and ‘bend end positions’.
SPECIFICATION DOCUMENT No.
FOR
A286-000-11-42-SP-12 Rev. 0
PIPELINE INFORMATION
MANAGEMENT SYSTEM (PIMS) Page 1 of 8
SPECIFICATION
FOR
MANAGEMENT SYSTEM (PIMS)
0 10.09.12 ISSUED AS JOB SPECIFICATION AA NR MSG
A 19.07.12 ISSUED FOR CLIENT’S COMMENT AKS RK RK

Date Purpose
No by by by
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 2 of 8
CONTENTS
1.0 INTRODUCTION……………………………………………………………………………..3
2.0 DETAILED PIMS SCOPE OF WORK……………………………………………………..3
3.0 OTHER REQUIREMENTS OF PIMS………………………………………………………6
4.0 CONTRACTOR'S RESPONSIBILITY……………………………………………………..7
5.0 DOCUMENTATION…….…………………………………………………………………...8
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 3 of 8
1.0 INTRODUCTION
The Pipeline Information Management System (PIMS) is a web based solution,

designed to monitor the construction progress on real time basis. Data that is
entered on daily basis is indexed and linked with scanned documents that provide
validated data. Reports are generated in a telescopic format that helps to browse
from the route map to details of each pipe laid. The solution is designed to provide
real time information about pipeline laying progress alongwith all associated works
including stations / terminal works during following stages such as project planning,
project execution / construction, pre-commissioning & commissioning, operation &
maintenance.
The software solution has the minimum following features to handle, manage the
data for all major activities of pipeline project.
1.1 The Pipeline Information Management System (PIMS) is a web based solution,
designed to:
Act as a Monitoring System

Provide help in making decisions & construction planning purpose
Show real time progress on the web
Online Report Generation
Archive Documents online
Consolidate all information in a centralized database
Help in project execution / construction, pre-commissioning & commissioning
Use of stored data during operation and maintenance of pipeline
2.0 DETAILED PIMS SCOPE OF WORK
2.1 The scope of work includes all materials, hardware, software, manpower, services
etc. required for customized pipeline data information management solution for the
pipeline project. For details refer Scope of work Document No: A286-000-11-42-
SOW-0002.
o Progress of each activity to be tracked separately and all procedures &
reports shall be linked to the data. Reporting formats shall be customized as
per the pipeline project requirements.
o The construction progress of the project on a real time basis updated daily.
The progress needs to be displayed electronically on a web based format.
Proper secured access is to be provided to the consultant and client enabling
review of construction progress on a daily basis.
o Apart from storing all paper documentation the software should have
requisite feature / facility to generate as built alignment sheets from varying
points of the pipeline route.
o The software should also have the feature / facility that the daily progress
can be shown on a web, with progress of different activities, geo-referenced
to the surroundings land base.
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 4 of 8
o All NDT test reports (including weld X-ray or AUT) require to be handed over
to the client in an electronic format, duly geo referenced as part of the
software archival features.
o The software solution chosen by the contractor should have been used and
tested on previous pipeline projects.
2.2 SCANNING, CATALOGUING AND DATA ENTRY

Scanning, cataloguing, indexing and retrieval of all project related documents
including but not limited to the following:
2.2.1 Line Pipe and Induction Bending information
All activities related to line pipe manufacturing and induction bending are required
to be tracked and monitored through PIMS and their related evidence documents to
be uploaded and hyperlinked suitably.
2.2.2 Material Information
All activities related to the materials (free issue & contractor supply) are required to
be tracked and monitored through PIMS and their related evidence documents to be
uploaded and hyperlinked suitably.
2.2.3 Material Acceptance
All materials manufacturers test certificates of consumables such as field joint
coating materials and electrodes and their site qualifications are required to be
tracked and monitored through PIMS and their related evidence documents to be
2.2.4 Procedure and Reports
Approved construction procedures, Job Procedures, welding procedures
specification & qualification, QAP’s and ITP’s for all pipeline activities including
Despatch / Receipt Terminal and SV Stations etc including scanning and digitisation
of Gazette notifications available with the owner.
2.2.5 Pipeline Construction Work Information
All construction activities of pipeline such as route survey, clearing & grading,
trenching, stringing, bending, welding, NDT, field joint coating, concrete weight
coating, OFC laying & splicing, lowering, backfilling, tie-ins, crossings & restoration
etc including all activities (Civil, Structural, Architectural, Mechanical, Electrical,
Instrumentation etc) related to terminal works are required to be tracked and
monitored through PIMS and their inspection reports to be uploaded and
hyperlinked suitably.
2.2.6 Cadastral survey documents

The entire cadastral survey data (to be provided by survey agency) has to be
uploaded which shall include the following as minimum and hyperlinked suitably:
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 5 of 8
o Surveys nos.
o Ownership area of affected survey no. in ROU
o Permanent feature along centre of pipeline
o Village maps, Talukas, Districts etc.
o Nearest police station with details, hospital, fire station, village panchayat,
district authority details
2.2.7 Land acquisitions details
The land acquisition details have to be uploaded which shall include the following as
minimum and hyperlinked suitably:
o The land owner details including the permanent and alternative address
o Mutation details
o Land usage details of the property owner including the crop details
o The information on the compensation paid to owner
2.2.8 Clearance and Restoration
All relevant activities related to clearance/permissions and restoration acceptance
from statutory authorities such as Forest Department, Railways & PWD etc. are
required to be tracked and monitored through PIMS and their status reports to be
2.2.9 Hydrostatic testing and Pre-commissioning & Commissioning
Following activities related to hydrostatic testing and pre-commissioning are
required to be tracked and monitored through PIMS and their inspection reports to
be uploaded and hyperlinked suitably.
o Water Filling, Pressurization & Hydrostatic test
o Dewatering
o Magnetic Cleaning
o Electronic Geometric Pigging (EGP)
o Swabbing & Drying
o Inertization, preservations, inspection, commissioning
2.3 Management Information System

2.3.1 Pre-construction and post-construction linkage with videography, digital photographs
at terminals/ stations, crossings (at least 100m on either side of railway, SH, NH and
river crossings) and SV stations on route map shall be provided.
The following shall be linked to schematic route map to provide information during
operation of the pipeline.
o Pipe book with all details
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 6 of 8
o As built Alignment sheets

o As built drawings for crossings and their photographs
o Station General Arrangement Drawings (SV, terminals), isometrics, layout,
P&ID etc
o Data Sheet of Equipment such as filters, metering and scraper traps etc.
o Test certificates – Pipe, pipe coating, equipment, and contractor supplied
items, etc.
o All SV/ turning points/ crossing/ km posts/ warning signs/ scraper stations shall
be geo-referenced.
o All required scanning, cataloguing and data entry as required for successful
operation of the system.
3.0 OTHER REQUIREMENTS OF PIMS
o The software system/package of data information management system shall

be able to function on a LAN/ WAN, minimum 75 concurrent users, with
adequate provision of security. The software package should be a web based
system providing simultaneous access to the CONTRACTOR, GIGL and EIL.
o The system shall enable quick retrieval and printing of relevant pipeline data/
as built information through a suitable application.
o The proposed system shall be equipped with security facilities to prevent data
tampering, data theft, sabotage and virus attack
o The CONTRACTOR shall collect, store, classify, handle and protect all input
data and acquired data in good shape till completion and handing over of
finished work. CONTRACTOR shall not make any unauthorised alteration,
modification and copies of any input data unless explicitly authorised by the
OWNER. All input and acquired data shall be returned to the OWNER at the
completion of work in its original form.
3.1.1 PIMS Features

o Monitoring of pipeline construction activities
o Linking of surrounding landmarks and data in corridor
o Data updating on a daily basis
o Generation of S Curves based on percentages (weightage) of activities
o Generation of alignment sheets
o Real time pipeline laying progress monitoring
o Monitoring of material availability and quality documents
o Uniformity of documentation and reports
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 7 of 8
o Real time creation of pipe book

o Real time creation of welder performance reports, pipe reconciliation reports.
o Pre hydrostatic test and pre-lowering compliance report generation
o Security of data base and world class data recovery management
3.1.2 Real time web progress monitoring
 Dynamic generation of Daily Progress Report (DPR) with planned time line and
asking rate.
 Real time generation of pipe book with attached Inspection test reports
 Tie in Chart with complete history of each activity of each joint
 The list of minimum activities digitized for monitoring are as follows:
o Pre-Construction Survey
o ROU Clearing & Grading
o Stinging
o Cold Field Bending
o Trenching
o Welding
o NDT
o Welding Repair
o Joint coating
o Coating Repair
o Lowering
o Back Filling
o Tie-in Welding
o Soil Stabilization
o Bank Protection for Rivers
o Restoration
o Hydrostatic Testing
o FOC
o TCP / PCP
o Crossings
o HDD
o Augur Boring/ Cased Crossings
o Open Cut Crossings
o Concrete Weight Coating/ Other anti-buoyancy measures
3.1.3 Training
Training shall be imparted to the client and consultant personnel on usage of the
PIMS solution and its application/ maintenance.
4.0 CONTRACTOR’S RESPONSIBILITY
4.1 The CONTRACTOR shall be solely responsible for arranging all resources, facilities
and logistic supports etc. required to complete the work under this contract. In
broad, the CONTRACTOR shall be responsible for providing the following:
o Establishment of a suitable onsite office with proper storage and security
arrangement.
DOCUMENT No.
SPECIFICATION
FOR
A286-000-11-42-SP-12 Rev. 0
Page 8 of 8
o Deployment of requisite manpower for project implementation (onsite and

offsite). The persons employed by the Contractor shall be technically qualified
and trained in development of requisite software and operation of various
computer applications. They should also have experience of data collection &
monitoring of pipeline construction.
o The contractor shall provide boarding & lodging arrangement for his personnel
at all locations during execution of work under the contract. The contractor
shall also provide boarding, lodging and transport arrangement for his
personnel during visit to ROW for collection of data for GIS mapping.
o Deployment of all requisite hardware (servers, computers, printers, scanners,
UPS, etc.) loaded with requisite software to run applications required for the
project implementation
o All consumables for scanning, printing, storing, and creation of backup data
CD’s/DVDs.
o Establishment of suitable communication network with a provision of Internet
connection for communication, email and uploading and downloading of
scanned documents.
o The integrity and confidentiality of the OWNER’s information assets are to be
maintained.
The scope of work shall also include any other item/ work required to complete the
work in all respect as per specifications and instructions of OWNER’s representative
whether specifically mentioned here-in or not, but required to fulfil the intended
purpose of tender document and this specification.
5.0 DOCUMENTATION
The bidder shall submit information about the Agency’s experience in providing such
a solution. A project specific detailed methodology to carry out all the above
activities shall be submitted along with bid. The sub-contractor, if any, and his
software shall be approved by OWNER.
BOLT DIRECTORY A286-000-11-42-SP-24 Rev. 0
Page 1 of 2

PIPELINE PROJECT
BOLT DIRECTORY
0 08.09.12 DOC. NO. CHANGED & ISSUED FOR BIDS SG NR MSG
A 09.08.12 ISSUED FOR BIDS SG NR MSG

Date Purpose
No by by by

JOB SPECIFICATION No..
BOLT DIRECTORY A286-000-11-42-SP-24 Rev. 0
Page 2 of 2
1.0 RF / FF STUD BOLT (150 # )
Bolt Length
Nom No of
Bolt Dia Flange to With Fig 8
Dia Bolts
Flange Flange
0.5 4 0.5 2.5 2.5
0.75 4 0.5 2.75 2.75
1 4 0.5 2.75 2.75
1.5 4 0.5 2.75 3.25
2.0 4 0.625 3.25 3.75
3.0 4 0.625 3.75 4.0
4.0 8 0.625 3.75 4.25
6.0 8 0.75 4.0 4.75
8.0 8 0.75 4.25 5.0
10.0 12 0.875 4.75 5.5
12.0 12 0.875 4.75 5.75
2.0 RF / FF STUD BOLT ( 600 # )
Bolt Length
Nom No of
Bolt Dia Flange to With Fig 8
Dia Bolts
Flange Flange
0.5 4 0.5 3.0 3.5
0.75 4 0.625 3.5 4
1 4 0.625 3.5 4
1.5 4 0.75 4.25 4.75
2.0 8 0.625 4.25 4.75
3.0 8 0.75 5.0 5.75
4.0 8 0.875 5.75 6.5
6.0 12 1.0 7.75 8.75
8.0 12 1.125 8.625 9.875
10.0 16 1.25 9.75 11.25
12.0 20 1.25 10.0 11.75
14.0 20 1.375 10.625 12.625
16.0 20 1.5 11.5 13.75
18.0 20 1.625 12.375 14.625
20.0 24 1.625 12.875 15.625
24.0 24 1.875 14.875 17.875
26.0 28 1.875 15.0 18.5
28.0 28 2.0 15.75 19
30.0 28 2.0 16 19.5
32.0 28 2.25 17 21
34.0 28 2.25 17.25 21.5
36.0 28 2.5 18.25 22.5
38.0 28 2.25 19.75 24.5
40.0 32 2.25 20.25 25

Document No.
BOLT TIGHTENING TORQUE AND A286-000-16-54-DD-0270
TENSION VALUES FOR D1A CLASS Rev. No. 0
SIZES 28 INCHES TO 36 INCHES Page 1 of 3
5
BOLT TIGHTENING TORQUE AND

TENSION VALUES FOR D1A CLASS
SIZES 28 INCHES TO 36 INCHES
MBPL, GSPL
0 16-08-12 ISSUED FOR TENDER NG PG SVRS

Reviewed Approved
Rev. No Date Purpose Prepared by
by by
Template No. 5-0000-0001-T1 Rev. 1 Copyrights EIL – All rights reserved

Document No.
BOLT TIGHTENING TORQUE AND A286-000-16-54-DD-0270
TENSION VALUES FOR D1A CLASS Rev. No. 0
SIZES 28 INCHES TO 36 INCHES Page 2 of 3
5
CONTENTS
1.0 BOLT TIGHTENING TORQUE AND TENSION VALUES FOR D1A 3
CLASS SIZES 28 INCHES TO 36 INCHES

BOLT TIGHTENING TORQUE AND Document No.
TENSION VALUES FOR D1A CLASS A286-000-16-54-DD-0270
SIZES 28 INCHES TO 36 INCHES Rev. No. 0
Page 3 of 3
5
1.0 BOLT TIGHTENING TORQUE AND TENSION VALUES FOR D1A CLASS SIZES 28 INCHES TO 36 INCHES
Design Test Materials Gasket Bolt Bolt

Sl. Line Size Flange Bolt No.
No Spec (in) rating Press., Temp., press.2 type/
size of bolts
tension, torque,
Flange Pipe Bolt
kg/cm2 °C kg/cm material kg kg-m
1 D1A 28.00 600 99.93 65 150.00 A 694 GR.F-52 API 5L GR.X-52 PSL2 A193 Gr. B7 SW SS316 2 28 35496 376.0
2 D1A 30.00 600 99.93 65 150.00 A 694 GR.F-52 API 5L GR.X-52 PSL2 A193 Gr. B7 SW SS316 2 28 39708 420.7
3 D1A 32.00 600 99.93 65 150.00 A 694 GR.F-52 API 5L GR.X-52 PSL2 A193 Gr. B7 SW SS316 2 1/4 28 46579 551.3
1
Note:
1. Refer to "Standard Specification for Application of Torque and Hydraulic Bolt Tension for Flange Joints" doc no 6-76-0002 rev 1 for criteria,
methodology and guidelines for application of the above values.

WELDING SPECIFICATION JOB SPECIFICATION No.
CHARTS FOR MEHSANA- A286-000-06-41-WSC-01
BATHINDA MAIN LINE AND Rev. 1
SPUR LINES OF GIGL Page 1 of 6
WELDING SPECIFICATION CHARTS

FOR MEHSANA-BATHINDA MAIN LINE
AND SPUR LINES
GSPL INDIA GASNET LIMITED
1 24.09.2012 Reissued for Implementation SKM PC SG
0 7.08.2012 Issued for Implementation SKM PC SG

Rev.
Date Purpose Prepared by Checked by Approved by
No

BATHINDA MAIN LINE AND Rev.1
Line Pipe: Palanpur DT To Bathinda RT ( 36” OD – Thicknesses. : 13.0/15.9/19.1mm)

Spur Line: Mangaliyawas Top (SV-4012) to Chittorgarh RT ( 24” OD – thk. ranges : 8.7/10.3/12.7 mm)
PIPES API 5L GR.X–70 PSL2
FITTINGS -
MATERIAL
SPECIFICATIONS FLANGES -
OTHERS -
BASE METAL `S’ NO 1

GROOVE JOINTS
WELDING PROCESS
BUTT OTHER THAN BUTT
ROOT PASS: GMAW-P FILLERPASS: GMAW-P /
(NOTE-1) FCAW (GAS SHIELDED) ROOTPASS: NA FILLER PASS: NA
(NOTE-1)
FILLET JOINTS/ SOCKET JOINTS: NA
GROOVE JOINTS
FILLER PASS: ASME SFA 5.28
ROOT PASS: ASME SFA 5.18
ER80S-G / ASME SFA 5.29
WELDING MATERIALS ER70S-G (NOTE-3) ROOT PASS: NA FILLER PASS: NA
E81T1-GM-H4 (NOTE-2, 3)
(NOTE-5)
FILLER JOINT/SOCKET JOINT: NA
BACKING RING: NA CONSUMABLE INSERT: NA
JOINT PREPARATION ASME B31.8
GASES PURGING: - SHIELDING: Ar + CO2 MIXTURE

GAS COMPOSITION PURGING: - SHIELDING: 80 - 85 % Ar + 15 - 20 % CO2
PREHEATING PREHEAT TEMP: 100°C MINIMUM POST HEATING: -
CONTINUITY OF WELDING AND PREHEAT: REFER TO SPECIFICATION
HOLDING TEMP: - HOLDING TIME: -
POST WELD HEAT TREATMENT RATE OF HEATING: - MIN. HOLDING TIME: -
METHOD OF COOLING: - RATE OF COOLING: -
MECHANICAL PROPERTY CHARPY `V’ NOTCH VALUE: (NOTE-4) MIN: 27 J AVERAGE: -

REQUIREMENTS
-20C OR LOWER DESIGN METAL
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
CODE OF FABRICATION ASME B31.8
TECHNICAL NOTES:
1. THIS WELDIGN CHART IS APPLICABLE FOR AUTOMATIC OR SEMIAUTOMATIC WELDING OF API 5L GR.X70-PSL-2
LINE PIPES.
2. EACH BATCH OF THE WELDING CONSUMABLE SHALL MATCH THE MINIMUM YIELD STRENGTH AND UTS VALUES OF
THE LINEPIPE (API 5L GR.X-70 PSL2).
3 WELDING CONSUMABLES QUALIFICATION SHALL BE CARRIED OUT AS PER THE LATEST EDITION OF ASME SECTION
II PART C.
4 DURING PROCEDURE QUALIFICATION TESTING, THE MINMUM IMPACT VALUE OF 27 J AT -20°C OR LOWER DESIGN
METAL TEMPERATURE SHALL BE MET.
5 ONLY NICKEL BASED E81T1-GM-H4 FILLER WIRE, SHALL BE USED FOR FILLER PASSES.
6 THIS WELDING SPECIFICATION CHART SHALL BE READ IN CONJUNCTION WITH THE WELDING SPECIFICATION
(A286-000-06-41-WSP-01 Rev.1).

Line Pipe: Palanpur DT To Bathinda RT ( 36” OD – Thicknesses. : 13.0/15.9/19.1mm)

Spur Line: Mangaliyawas Top (SV-4012) to Chittorgarh RT ( 24” OD – thk. ranges : 8.7/10.3/12.7 mm)
FITTINGS -
MATERIAL
OTHERS -

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW (NOTE-1)
FILLERPASS: SMAW (NOTE-1) ROOTPASS: NA FILLER PASS: NA
GROOVE JOINTS
E7018-1-H4R (NOTE-1, 3) FILLER PASS: ASME SFA 5.5
WELDING MATERIALS ROOT PASS: NA FILLER PASS: NA
E8018-G (NOTE-1, 2, 3)

GASES PURGING: - SHIELDING:

GAS COMPOSITION PURGING: - SHIELDING:

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. THIS WELDING CHART IS APPLICABLE FOR MANUAL WELDING OF API 5L GR.X70-PSL-2 LINE PIPES. ANY DEVIATION
FROM THE VENDOR IS NOT ACCEPTABLE.
3. WELDING CONSUMABLES QUALIFICATION SHALL BE CARRIED OUT AS PER THE LATEST EDITION OF ASME SECTION
II PART C.
4. DURING PROCEDURE QUALIFICATION TESTING, THE MINMUM IMPACT VALUE OF 27 J AT -20°C OR LOWER DESIGN
5. THIS WELDING SPECIFICATION CHART SHALL BE READ IN CONJUNCTION WITH THE WELDING SPECIFICATION
(A286-000-06-41-WSP-01 Rev.1).

Palanpur DT To Bathinda RT ( 36” OD – Thicknesses. : 13.0/15.9/19.1mm); Mangaliyawas Top (SV-4012) to

Chittorgarh RT ( 24” OD – thk. ranges : 8.7/10.3/12.7 mm)
FOR TIE-IN JOINTS & CROSSINGS ONLY (NOTE-1)
FOR TIE-IN JOINTS & CROSSINGS ONLY API
PIPES 5L GR.X–70 PSL2
(NOTE-1)
FITTINGS -
MATERIAL
OTHERS -

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW
FILLERPASS: SMAW ROOTPASS: NA FILLER PASS: NA
GROOVE JOINTS
E7018-1-H4R (NOTE-3) FILLER PASS: ASME SFA 5.5
E8018-G (NOTE-2, 3)

GASES PURGING: - SHIELDING:

GAS COMPOSITION PURGING: - SHIELDING:

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. MANUAL WELDING PROCESS IS APPLICABLE FOR TIE-IN JOINTS AND CROSSINGS ONLY.
3. WELDING CONSUMABLES QUALIFICATION SHALL BE CARRIED OUT AS PER THE LATEST EDITION OF ASME SECTION II
PART C.
5. THIS WELDING SPECIFICATION CHART SHALL BE READ IN CONJUNCTION WITH THE WELDING SPECIFICATION (A286-
000-06-41-WSP-01 Rev.1).

Dudu DT (SV-4015) to Bhiwadi RT ( 18” OD – Thk. ranges : 7.1/8.7/10.3/12.7mm); Sidhmukh DT (SV-4024) to Rohtak
RT ( 18” OD – Thk. ranges : 7.1/8.7/10.3mm); Bhamin DT (SV-4028) to GGSRL RT ( 18” OD – Thk. ranges :
7.1/8.7/10.3mm); Dhanin Top (SV-2502) to Udaipur RT ( 12” OD – Thk. ranges: 6.4/7.9mm); Isali Top (SV-4008) to
Jodhpur RT ( 12” OD – Thk. ranges: 6.4/7.9mm); SV-1903 to Hisar RT (12” Thk. ranges: 6.4/7.9mm)
FITTINGS -
MATERIAL
OTHERS -

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: GMAW/SMAW FILLERPASS: GMAW/SMAW/
ROOTPASS: NA FILLER PASS: NA
FCAW
GROOVE JOINTS
ROOT PASS: ASME SFA 5.18 FILLER PASS: ASME SFA 5.28
ER70S-G / ASME SFA 5.1 ER80S-G / ASME SFA 5.5
E6010 (NOTE-1) E8018-G / ASME SFA 5.29
E81T-1M (NOTE-1)
GASES PURGING: - SHIELDING: Ar + CO2 MIXTURE

GAS COMPOSITION PURGING: - SHIELDING: 80 - 85 % Ar + 15 - 20 % CO2

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. WELDING CONSUMABLES QUALIFICATION SHALL BE CARRIED OUT AS PER THE LATEST EDITION OF ASME SECTION
II PART C.
(A286-000-06-41-WSP-01 Rev.1).

Karoi DT (SV-2505) to Bhilwara RT( 8” OD – Thk.: 6.4mm), Rajosi DT (SV-4013) to Ajmer RT ( 8” OD – Thk.: 6.4
mm), Mandha DT (SV-1707) to Alwar RT( 8” OD – Thk.: 6.4mm)
FITTINGS -
MATERIAL
OTHERS -

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: SMAW
FILLERPASS: SMAW ROOTPASS: NA FILLER PASS: NA
GROOVE JOINTS
ROOT PASS: ASME SFA 5.1 FILLER PASS: ASME SFA 5.5
WELDING MATERIALS E6010 (NOTE-1) E7010-P1 (NOTE-1) ROOT PASS: NA FILLER PASS: NA

GASES PURGING: - SHIELDING: -

GAS COMPOSITION PURGING: - SHIELDING: -

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. WELDING ELECTRODE QUALIFICATION SHALL BE CARRIED OUT AS PER THE LATEST EDITION OF ASME SECTION II
PART C.
(A286-000-06-41-WSP-01 Rev.1).

BATHINDA TERMINAL PIPING Rev. 1
OF GIGL Page 1 of 4
WELDING SPECIFICATION CHARTS

FOR MEHSANA-BATHINDA TERMINAL
PIPING
1 24.09.2012 Reissued for Implementation SKM PC SG
0 29.08.2012 Issued for Implementation SKM PC SG

Rev.
No

BATHINDA TERMINAL PIPING Rev.1
OF GIGL Page 2 of 4
PIPING CLASS: A4A, D21A

PIPES ASTM A 333 GR.6
FITTINGS ASTM A 350 GR.LF2, ASTM A 420 GR.WPL6
MATERIAL
SPECIFICATIONS FLANGES ASTM A 350 GR.LF2
OTHERS -
BASE METAL `P’ NO 1

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: GTAW FILLERPASS:GTAW FILLER PASS: GTAW

ROOTPASS: GTAW
(NOTE-1) / SMAW (NOTE-1) / SMAW
FILLET JOINTS/ SOCKET JOINTS: SMAW
GROOVE JOINTS
ROOT PASS: ER80S-Ni1

FILLER PASS: ER80S-Ni1/ ROOT PASS: ER80S-Ni1 FILLER PASS: ER80S-Ni1/
WELDING MATERIALS (NOTE-2)
E7018-1 (NOTE-2) (NOTE-2) E7018-1 (NOTE-2)
FILLER JOINT/SOCKET JOINT: E7018-1 (NOTE-2)

GASES PURGING: - SHIELDING: ARGON

GAS COMPOSITION PURGING: - SHIELDING: 99.995 %

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. ALL PIPING SIZES 2” AND BELOW SHALL BE ENTIRELY WELDED BY GTAW PROCESS.
2. WELDING FILLER MATERIAL QUALIFICATION SHALL BE CARRIED OUT AS PER THE LATEST EDITION OF ASME
SECTION II PART C.
(A286-000-06-41-WSP-01 Rev.1).

OF GIGL Page 3 of 4
PIPING CLASS: D1A

(WELDING BETWEEN Gr.70/65 to A 333 Gr.6 or API 5L Gr.52/60 or MSS SP-75Gr.WPHY-52/60 or ASTM A 694
Gr.F52/60 AND WELDING AMONG A 333 GR.6, API 5L Gr.52/60, MSS SP-75Gr.WPHY-52/60, ASTM A 694
Gr.52/60)
ASTM A 333 GR.6, API 5L GR.X-52 PSL2, API 5L GR.X-60 PSL2, API 5L
PIPES GR.X-65PSL2, API 5L GR.X-70 PSL2
ASTM A 420 GR.WPL6, MSS SP-75 GR.WPHY-52, MSS SP-75 GR.WPHY-
MATERIAL FITTINGS 60, MSS SP-75 GR.WPHY-65, MSS SP-75 GR.WPHY-70, ASTM A 694
SPECIFICATIONS GR.F60
ASTM A 350, ASTM A 694 GR.F52, ASTM A 694 GR.F60, ASTM A 694
FLANGES
GR.F65, ASTM A 694 GR.F70
OTHERS -

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: GTAW/SMAW ROOTPASS: GTAW/ FILLER PASS: GTAW /
FILLERPASS: GTAW/SMAW
SMAW SMAW
GROOVE JOINTS
ROOT PASS: ER70S-2

ROOT PASS: ER70S-2 /E6010 FILLER PASS: ER70S-2/E7018 FILLER PASS: ER70S-2
WELDING MATERIALS (NOTE-1) / E6010
(NOTE-2) (NOTE-2) /E7018 (NOTE-2)
(NOTE-2)
FILLER JOINT/SOCKET JOINT: E7018 (NOTE-2)


GAS COMPOSITION PURGING: - SHIELDING: 99.9955 % Ar
PREHEATING PREHEAT TEMP: 150°C MINIMUM (NOTE-3) POST HEATING: -

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. MANUAL WELDING IS RECOMMENDED ONLY FOR TERMINAL PIPING.
SECTION II PART C.
3. PREHEATING IS REQUIRED WHEN CELLULOSIC ELECTRODE (E6010) IS USED.
(A286-000-06-41-WSP-01 Rev.1).

OF GIGL Page 4 of 4
PIPING CLASS: D1A (Gr.65/70 to Gr.65/70) (NOTE-1)

PIPES API 5L GR.X-65 PSL2, API 5L GR.X-70 PSL2
FITTINGS MSS SP-75 GR.WPHY-65, MSS SP-75 GR.WPHY-70

MATERIAL
SPECIFICATIONS ASTM A 694 GR.F65, ASTM A 694 GR.F70
FLANGES
OTHERS -

GROOVE JOINTS
WELDING PROCESS
ROOT PASS: GTAW/SMAW ROOTPASS: GTAW/
FILLERPASS: SMAW FILLER PASS: SMAW
SMAW
GROOVE JOINTS
ROOT PASS: ER70S-2

ROOT PASS: ER70S-2 /E6010 FILLER PASS: E8018-G FILLER PASS: E8018-G
WELDING MATERIALS (NOTE-1) / E6010
(NOTE-2) (NOTE-2) (NOTE-2)
(NOTE-2)
FILLER JOINT/SOCKET JOINT: E8018-G (NOTE-2)

BACKING RING: NA CONSUMABLE INSERT: E8018-G

GAS COMPOSITION PURGING: - SHIELDING: 99.9955 % Ar
PREHEATING PREHEAT TEMP: 150°C MINIMUM (NOTE-3) POST HEATING: -

REQUIREMENTS
AT TEMPERATURE:
TEMPERATURE
HARDNESS:
TECHNICAL NOTES:
1. MANUAL WELDING IS RECOMMENDED ONLY FOR TERMINAL PIPING.
SECTION II PART C.
3. PREHEATING IS REQUIRED WHEN CELLULOSIC ELECTRODE (E6010) IS USED.
(A286-000-06-41-WSP-01 Rev.1).

FOR MEHSANA-BATHINDA A286-000-06-41-WSP-01
MAIN LINE AND SPUR LINES Rev. 1
OF GIGL
Page 1 of 48
WELDING SPECIFICATION FOR

MEHSANA-BATHINDA MAIN LINE AND
SPUR LINES
1 24.09.2012 REISSUSED FOR IMPLEMENTATION SKM PC SG
0 7.08.2012 ISSUSED FOR IMPLEMENTATION SKM PC SG

Rev.
No
FOR MEHSANA-BATHINDA
A286-000-06-41-WSP-01
MAIN LINE AND SPUR LINES
Rev. 1
OF GIGL
Page 2 of 48
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
13.0 REPAIR OF WELDS
ANNEXURE – 1 : DESTRUCTIVE TESTING

ANNEXURE – 2 : ULTRASONIC INSPECTION
ANNEXURE – 3 : AUTOMATIC ULTRASONIC TESTING
ANNEXURE – 4 : RADIOGRAPHY
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
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 3 of 48
1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of welded
joints of carbon steel main pipeline (Mehsana to Bathinda), spur lines and related facilities.
Natural Gas will be transported through this pipeline.
The welded pipe joints shall include the following:
a) All line pipe joints of the longitudinal and circumferential butt- welded and socket welded
types.
b) Attachments of castings, forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded/fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other instrument
tappings.
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
2.0 APPLICABLE CODE AND STANDARDS
All welding work, equipment for welding, heat treatment, other auxiliary functions and the
welding personnel shall meet the requirements of the latest editions of the codes, standards
and specifications listed below:
a) Code for Gas Transmission and Distribution Piping Systems, ANSI B31.8.
b) Standard for Welding of Pipelines and Related Facilities, API 1104.
c) Specification for Welding Electrodes and Filler Materials, ASME Sec. II Part C.
d) Non-Destructive examinassions, ASME Sec. V.
e) Welding Specification Charts for Mehasana-Bathinda Main line and Spur lines of GIGL,
A286-000-06-41-WSC-01 Rev.1
f) Welding Specification Charts for Mehasana-Bathinda Terminal piping of GIGL, A286-000-

06-41-WSC-02 Rev.1
3.0 BASE MATERIAL
a) In general carbon steel is used in this specification. The details of material specifications
are given in the welding Specification Chart attached along with other project data sheets.
The CONTRACTOR will arrange and maintain the record of test certificates of all the
materials for the reference of the welding engineer.
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 4 of 48
4.0 WELDING CONSUMABLES
a) The CONTRACTOR shall provide at his own expense all the welding consumables
necessary for the execution of the job such as electrode/filler wire, oxygen, acetylene etc.
and these shall bear the approval of the COMPANY.
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 electrode 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 electrode 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 electrodes shall be handled with care
to avoid any damage to the flux covering. Different grades of electrodes shall be stored
separately. Cellulosic electrodes shall be used as per the specific recommendation made by
the manufacturer.
g) The electrodes 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, when required by the welding
processes other than Shielded Metal Arc Welding (SMAW) process, CONTRACTOR shall
bear the approval of the COMPANY. An appropriate gases or gas mixture of the following
quality shall be used.
1. Argon gas complying with BS 4365.

2. Carbon dioxide gas complying with type 1 specified in BS- 4105
3. Gas mixtures that have been proved to be satisfactory as a result of procedure approval
tests.
When a gas mixture is used, which has specified additions viz. 2% O2, 5% CO2, the
variation of such addition shall not exceed +10% of that stated. Moisture content shall
correspond to a dew point of -300C or lower.
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 5 of 48
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 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 the wrong operation carried out
by the CONTRACTOR shall be done at his own expense.
6.0 WELDING PROCESSES
6.1 Welding of various materials under this specification shall be carried out using the following
process.
6.1.1 Main Line (36”Ø Palanpur DT To Bathinda RT - API 5L Gr.X70 PSL2)
Welding can be carried out by automatic, semi-automatic or manual welding process.

During automatic and/or semi-automatic welding, the root shall be carried out by GMAW-P
process and the filler passes from outside can be carried out by GMAW-P/FCAW process.
When welding is carried out only from outside, copper backing shall be used at the root side.
6.1.2 Spur Lines (24”Ø Mangaliyawas Top (SV-4012) to Chittorgarh RT - API 5L Gr.X70 PSL2)
Welding shall be carried out by automatic, semi-automatic or manual welding process.

During automatic and/or semi-automatic welding, the root shall be carried out by GMAW-P
process and the filler passes from outside can be carried out by GMAW-P/FCAW process.
When welding is carried out only from outside, copper backing shall be used at the root side.
6.1.3 Spur Lines (18”Ø Dudu DT (SV-4015) to Bhiwadi RT / Sidhmukh DT (SV-4024) to Rohtak
RT / Bhamin DT (SV-4028) to GGSRL RT, 12” Dhanin Top (SV-2502) to Udaipur RT/ Isali
Top (SV-4008) to Jodhpur RT/ SV-1903 to Hisar RT- API 5L Gr.X65 PSL2)
Welding shall be carried out by automatic, semi-automatic or manual welding process. The
root shall be carried out by GMAW-P/SMAW process. The filler passes from outside can be
carried out by GMAW-P/SMAW/FCAW process. When welding is carried out only from
outside using GMAW-P process, copper backing shall be used at the root side.
6.1.4 Spur Lines (8”Ø Karoi DT (SV-2505) to Bhilwara RT / Rajosi DT (SV-4013) to Ajmer RT /
Mandha DT (SV-1707) to Alwar RT - API 5L Gr.X52 PSL2)
Welding shall be carried out by manual welding process.
6.1.5 Tie-ins and Crossings

Semi-automatic Flux Cored Arc Welding or Shielded Metal Arc Welding with low hydrogen
consumables shall be used for tie-ins and crossings.
6.1.6 Double jointing of two pipe lengths using submerged arc welding in specially laid pipe
welding yard is also permitted.
Any deviation desired by the CONTRACTOR shall be obtained through the written consent of
the COMPANY.
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 6 of 48
Following agencies for Automatic Welding Systems are acceptable:

a) CRC-Evans Automatic Welding Systems, Houston
b) Pipe Welding Technology, Italy
c) RMS Welding Systems, Canada
d) Sermier Dasa, France
In case, the bidder proposes to employ any other agency, the proposed agency shall meet the
qualification criteria mentioned in the following paragraph and shall submit necessary
documentation meeting the criteria. The detailed system description and the procedure shall be
submitted to the COMPANY for evaluation and approval
“Automatic welding systems and agencies who have proven track record of high productivity
with satisfactory quality of weld and have done a single project of diameter 20” or above for a
minimum length of 50 km and for a cumulative length of 500 km or above on large diameter
Pipe lines in the last ten years shall only be accepted. CONTRACTOR shall engage only such
automatic welding systems and agencies for the work to be covered by main line automatic
welding. The track record shall be submitted to the COMPANY for approval prior to
engagement”.
6.2 The welding specification charts specifically developed for welding of the pipeline under this
project shall be followed. The welding procedure adopted and the consumables used shall be
specifically approved.
6.3 A combination of different welding processes or a combination of electrodes of different

classes/makes could be employed for a particular joint, only after duly qualifying the welding
procedures to be adopted and obtaining the approval of the COMPANY.
7.0 BEVEL CLEANING/BEVEL INSPECTION
The line pipe supplied by the COMPANY shall have bevel ends as specified in the applicable
specification for the line pipe attached with the Bid Package. Any modification thereto, if
required by the CONTRACTOR due to his special welding technique, shall be carried out by
the CONTRACTOR at his own cost. Before welding, all the rust and the foreign matter shall
be removed from the bevelled-ends by power operated tools. This shall be effected 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 bevelled with an approved
bevelling machine to the satisfaction of the COMPANY. Manual cutting and weld repairs of
bevels is not allowed. Should laminations, split ends or inherent manufacturing defects in the
pipe be discovered, the lengths of pipe containing such defects shall be removed. For such
pipes, the new bevel shall be examined 100% visually and 100% by dye-penetrant or MPI
method. A report shall be generated after carrying out the tests.
8.0 ALIGNMENT AND SPACING
Immediately prior to line-up, the CONTRACTOR shall inspect the pipe ends inside and
outside for damage, dents, laminations etc. Pipe for welding shall be set up, correctly spaced,
allowing for the temperature changes during welding. In correct 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, at least 500 mm above the ground unless approved
by the COMPANY in specific cases.
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 7 of 48
Seam orientation of welded pipe shall be selected to ensure that at the circumferential welds,
the longitudinal welds shall be staggered in the top 900 of the pipeline, or 250 mm whichever
is the lesser. A longitudinal joint shall pass an appurtenance of a structural element at a
minimum distance of 50 mm. Should a section of the line containing uncompleted welds fall
from the skids, the CONTRACTOR shall immediately inform the COMPANY.
Every effort shall be made to reduce misalignment by the use of the clamp and rotation of the
pipes to the best fit. For pipe of same nominal wall thickness, the offset shall not exceed 1.6
mm. The off set 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 any other weld. Cold dressing
is permissible only in cases of slight misalignment and may only be carried out with a bronze
headed hammer. Hot dressing 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 shall be subjected to both Ultrasonic and Radiography
inspection.
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 pipe 10” etc.) where it is
impossible to use internal clamps, an external line-up clamp may be used.
The internal line-up clamp shall not be released before the entire first pass has been
completed.
When an external line-up clamp is used, all the spaces between the bars or at least 60% of the
first pass shall be welded before the clamp is released and the pipe remaining adequately
supported on each side 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 approved
welding procedure.
b) Position or roll welding 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.
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 8 of 48
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 3 mm
wherever not specified by the applicable code.
d) Any deviations from the recommended welding technique and electrodes 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. 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 by a minimum of two welders/welding heads, working
simultaneously and so placed as to cause minimum distortion of the pipe.
The number of welders/ welding heads and the allowable welding sequences shall be as those
laid down in the Qualified Welding Procedure Specification (QWPS). Once the deposit of the
first pass has been started, it must be completed as rapidly as possible, reducing interruptions
to the minimum. The welding and wire speed shall be approximately same as that established
in the QWPS.
The pipe shall always be adequately supported and must not be bumped or shaken during
welding. The clamp shall be removed as indicated in Clause 8.0. Before starting the second
pass, the first pass shall be cleaned and flattened with rotating grinders.
The interruption between completion of the first pass and 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
which shows no under cutting.
The time lapse between the second and the third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or following
passes, welding operations may be suspended to allow the joint to cool down, provided the
thickness of the weld metal deposited is equal to at least 50% of the pipe thickness. Upon
restarting, depending on the materials, wall thickness and welding process, a preheating of at
least 1000C shall be applied. Subsequent passes up to weld completion shall be protected to
avoid rapid cooling, if meteorological conditions so dictate. Cleaning between the passes shall
be done carefully to reduce the possibility of inclusions.
The electrode 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 welding cable round and the pipe shall be
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 9 of 48
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 HEAT TREATMENT
11.1 Preheating
a) Preheating requirements for the various materials shall be as per the welding specification
chart attached.
b) Preheating shall be performed using resistance or induction heating methods.
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.
11.2 Post Weld Heat Treatment
a) Post weld heat treatment, wherever required for joints between pipes and fittings, pipe
body and supports shall be carried out by the CONTRACTOR at his expense as per the
relevant specifications, applicable standards and the instructions of the COMPANY.
b) The heat treatment of welded joint shall be carried out as per the requirements laid down in
ANSI B31.8 and other special requirements mentioned in welding specification chart.
c) The CONTRACTOR shall submit the post weld heat treatment procedure, as per Exhibit-B
attached well in advance to get the approval from the COMPANY, before carrying out the
actual heat treatments of the materials/assembly/part involved.
d) Post weld heat treatment shall be done in a furnace or by using an electric resistance or
induction heating equipment approved by the COMPANY.
e) While carrying out local post weld heat treatment, application of heat must be ensured to
attain the uniform temperature at all points of the portion being heat-treated. Care shall be
taken to ensure that the width of heated band over which specified post weld heat treatment
temperature maintained is at least as that specified in the relevant applicable
standards/codes.
f) The width of the heated band centered on the weld shall at least be equal to the width of
weld plus 2 inches (50 mm). The temperature gradient shall be such that the length of the
material on each side of the weld, at a temperature exceeding half the heat treatment
temperature, is at least 2.5rt where ‘r’ is the bore radius and‘t’ is the pipe thickness at the
weld.
A286-000-06-41-WSP-01
Rev. 1
OF GIGL
Page 10 of 48
g) Throughout the cycle of heat treatment, the portion outside the heated band shall be
suitably wrapped under insulation to avoid any harmful temperature gradient at the
exposed surface of pipe. For this purpose, temperature at the exposed surface of the pipe
shall not be allowed to exceed 4000C.
h) The temperature attained by the portion under heat treatment shall be recorded by means of
thermocouples. Adequate number of thermocouples shall be attached to the pipe directly at
equally spaced locations along the periphery of the pipe joint. The minimum number of
thermocouples attached per joint shall be 2 upto 10” dia., 3 for 12” dia. & above.
COMPANY can increase the required minimum number of thermocouples to be attached if
found necessary.
i) Automatic temperature recorders, which have been suitably calibrated, shall be employed.
The calibration chart of each recorder shall be submitted to the COMPANY to obtain
approval, prior to starting of the heat treatment operation.
j) Immediately on completion of the post weld heat treatment, hardness shall be measured on
the heat affected zone as well as of the weld metal using a suitable hardness tester in
Vickers hardness or Brinel hardness scale and the hardness value shall not exceed the
maximum hardness specified in the welding specification chart. The weld joint shall be
subjected to re-heat treatment at the CONTRACTOR’S own expense, when measured
hardness values exceed the specified limit.
k) The CONTRACTOR shall arrange for the hardness testing and shall maintain the records
of all the joints tested. These records shall be checked by the Inspector authorized by the
COMPANY.
l) The post weld heat treatment charts/records along with the hardness test results on the weld
joints (whenever required as per the welding specification chart) shall be submitted to the
COMPANY for its approval.
m) Each joint shall bear an identification number, which shall be maintained in the piping
sketch to be prepared by the CONTRACTOR. The joint identification number shall appear
on the corresponding post weld heat treatment charts. The same identification numbers
shall also be followed for identification of corresponding radiographic films. The chart
containing the identification number and the piping sketch shall be submitted to the
COMPANY.
12.1 General
a) The Inspector authorized by the COMPANY shall have free access to all the concerned
areas, where the actual work is being performed. The CONTRACTOR shall also afford the
Inspector all means and facilities necessary to carry out inspection.
b) The COMPANY is entitled to depute its own Inspector to the shop or field where pre-
fabrication and erection of pipelines are being done, with the following objectives, but not
limited to:
i) 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.

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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. 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 NDT requirements specified in Clause 12.5 and Annexure-
2, 3, 4 (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.
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
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alignment of the work, excessive reinforcement, concavity, shrinkage, cracks, under-cuts,

dimensions, surface porosity and other surface defects. Undercutting adjacent to the
completed weld shall not exceed the limits specified in the applicable code/standard.
12.5 Non-Destructive Examination
12.5.1 The non-destructive examination of one hundred percent (100%) girth welds shall be carried
out.
The non-destructive examination shall mainly consist of examination using Automated

Ultrasonic Testing (AUT) as detailed in Annexure-3. This shall be applicable for all welds
made by automatic GMAW with narrow bevels. Welds made with API bevels may be
examined either by Radiography or Automatic Ultrasonic examination. When Radiography is
used, the provisions stated in Clause 12.5.2 shall be applicable. Welds shall meet the standards
of acceptability as set forth in API 1104 as well as the requirements laid in subsequent
paragraphs.
The CONTRACTOR shall make all the arrangements for the Automated Ultrasonic Testing
of work covered by the specification at his expense. The CONTRACTOR shall furnish all the
reports to the COMPANY, immediately after examination together with the corresponding
interpretation reports on the approved format. The details of the AUT reports along with the
joint identification number shall be duly entered in a register and signed by the
CONTRACTOR and submitted to the COMPANY for approval. The COMPANY will review
all the Automatic Ultrasonic Testing records of welds and inform the CONTRACTOR to
those welds, which are unacceptable. The decision of the COMPANY shall be final and
binding in this regard.
All the requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, Radiography examination shall be
required in the following cases as per Annexure - 4 of this specification:
a) On the first 100 welded joints corresponding to each automatic GTAW/GMAW

welding procedure used.
b) When welds are repaired.
c) When in the opinion of COMPANY, Radiography inspection is required to confirm or

clarify defects indicated by Ultrasonic examination.
d) Welding of transition piece of pipe.
In addition, Radiography inspection may be required for certain critical welds of the pipeline,
i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet
and groove welds, other than those AUT examined, shall be subjected to Dye-Penetrant /MP
testing followed by manual Ultrasonic testing.
The non-destructive testing system used for inspecting welds must by approved by the
COMPANY.
12.5.2 Tie in and other welds having API bevel may be examined by Radiography or Automatic
Ultrasonic Testing. When Radiography is used, the provisions stated in this para shall be
applicable.
Welds shall meet the standards of acceptability as set forth in API 1104 and as well as the
requirements laid in subsequent paragraphs.
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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.
All the requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, Ultrasonic inspection is required in
the following cases as per Annexure - 2 of this specification:
a) On the first 10 welded joints corresponding to each automatic GTAW/GMAW welding

procedure used.
b) When welds are repaired.
c) When in the opinion of COMPANY, Ultrasonic inspection is required to confirm or

clarify defects indicated by Radiography.
In addition, Ultrasonic inspection may be required for certain critical welds of the pipeline, i.e.
tie-ins, welding of valves, flanges, randomly selected at COMPANY discretion. All fillet and
groove welds, other than those are subjected to Radiography, shall be subjected to Dye-
Penetrant/MP inspection. The non-destructive testing system used for inspecting welds must
by approved by the COMPANY.
12.5.3Acceptance Criteria
Weld quality as judged on the basis of the acceptability criteria mentioned below:
i) Any weld, which as a result of Radiography and/or Ultrasonic examination in the
opinion of COMPANY exhibits imperfections greater than the limits stated in API 1104
latest edition or as superseded in this article, shall be considered defective and shall so
be marked with an identification point marker.
ii) In addition to the API 1104 requirements, the welds containing cracks including crater
cracks regardless of size or location are unacceptable.
Suitable records shall be maintained by the CONTRACTOR on the day to day work
done on welding Radiography, Ultrasonic testing. The CONTRACTOR shall present
the records to the COMPANY on day-to-day basis and whenever demanded, for
approval.
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.
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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.
The repair shall be subjected, as a minimum requirement to the same testing and inspection
requirements as the original weld. Re-Radiography of the repaired area shall be carried out. In
addition, a minimum of 6” weld on either side of the repaired area shall be subjected to re-
Radiography. A 100% Ultrasonic testing shall be done at the repaired area externally. Any
repaired area that is wide, irregular or rough shall be rejected and a full cut out shall be done.
Single pass repairs shall be subjected to 100 % Dye-Penetrant/MP testing.
Repairs are limited to a maximum of 30% of the weld length. Not more than two repairs are
permitted on the same location. All repairs shall be carried out the day after initial
Radiography or earlier. A full report of all repairs made shall be submitted every day to the
COMPANY.
13.2 Weld Rejected by Accumulation of Defects
Where a weld is rejected by the accumulation of defect as defined by API-1104 and this
specification, repairs within these limitations are permitted. Defects in the filling and capping
passes shall be repaired preferentially.
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ANNEXURE - 1
1.0 DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS
1.1 PREPARATION OF SPECIMEN
Having passed the visual and the non-destructive inspection, the test weld shall be subjected to
mechanical test.
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.
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 & 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
PIPE
NUMBER OF SPECIMENS
SIZE,
OUT
SIDE TENSILE
DIA. NICK ROOT FACE
(INCH) SIDE BEND MACRO HARDNESS IMPACT TOTAL
BREAK BEND BEND
API ISO
WALL THICKNESS ½ INCH (12.7 mm) AND UNDER

UNDER
2 0 0 2 2 0 0 0 0 0 4
2 TO
4½
0 0 2 2 0 0 0 0 0 4
INCLU
DING
OVER
4½
LESS 2 0 2 2 2 0 2 2 12 24
THAN
12¾
12¾
AND 2 2 4 4 4 0 2 2 24 44
OVER
WALL THICKNESS OVER ½ INCH (12.7 mm)

4½
AND
0 2 0 0 0 2 0 0 0 4
SMALL
ER
OVER
4½
LESS 2 0 2 2 2 0 2 2 12 24
THAN
12¾
12¾
AND 2 2 4 0 0 8 2 2 24 44
OVER
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 1.5mm 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.
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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
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 metal.
Reference is made to FIG.3 of this specification. The indentations are to be made in the
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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Nominal wall thickness (mm) Test specimen width ( mm)

Over 12 10
12 to above 9.5 7.5
9.5 to 7 5
Less than 7 2.5
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:
Test specimen (mm) Average of three (3) Minimum single value
specimens, Min. (Joules) (Joules)
(Note 2) (Note 1)
10.0 27.0 22.0
7.5 21.5 17.5
5.0 18.5 15.0
2.5 10.0 8.0
Note 1: These values are specified for resistance to brittle fracture only. Where additional requirements are specified in
project data sheet, as for example, pipeline material with arrest properties i.e. a higher upper shelf Charpy V-
Notch energy for resistance against propagating ductile fractures, the same shall be followed.
Note 2: Only one value is permitted to be lower than average value up to the value specified.
1.7 BEND TEST REQUIREMENTS

The Bend test Specimens shall be made and tested as per the requirements of API 1104,
Nineteenth Edition, September 1999. The acceptance criteria shall however be as per para
5.6.4.3 and 5.6.5.3 of API 1104.However, the dimensions of the Jig for guided bend test in
Fig.9 shall be modified as specified below:
Radius of the Plunger À' = 2t
Radius of the die. `B' = 3t + 1.6 mm
Width of the die. `C' = 50.8
Where t = thickness of the specimen
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ANNEXURE - 2
1.0 ULTRASONIC INSPECTION
In addition to the Radiography inspection, Ultrasonic inspection 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 able to effect 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
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.
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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.
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.
1.7 REFERENCE SAMPLE PIECES
The efficiency of the equipment, the effective refraction angle of the probe, and the beam
output point shall be checked using a V1 and V2 sample block, IIW type or the calibration
block ASTM E-428.
For manual Ultrasonic testing and automated Ultrasonic testing, the reference sample pieces
shall be as described in API 1104, Nineteenth Edition, para 11.4.5.
1.8 CALIBRATION
The calibration, qualification of the testing procedure shall be done as provided in API 1104.
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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
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.
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
AUTOMATED ULTRASONIC TESTING (AUT)

1.0 INTRODUCTION
3.0 APPROVED AGENCIES
4.0 AUT SYSTEM
5.0 COUPLING
6.0 SEARCH UNITS
7.0 CALIBRATIONS
8.0 PROCEDURE
9.0 TRAINING AND QUALIFICATION
10.0 FIELD EXAMINATIONS AND REPORTING
11.0 INTERPRETATION OF RESULTS
12.0 ACCEPTANCE CRITERIA
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1.0 INTRODUCTION
The specification shall be applicable for Automated Ultrasonic Testing (AUT) system suitable
for pipeline girth welds. The system shall be based on focused pulse echo, tandem or through
transmission methods enhanced with mapping image and augmented by Time Of Flight
Diffraction (TOFD) technique.
ASTM E 1961-98 “Standard Practice for Mechanized Ultrasonic examination of Girth Welds
using Zonal Discrimination with Focused Search Units”. The inspection system shall meet and
exceed the requirements of ASTM E 1961-98.
Appendix-E, “Automated Ultrasonic Girth Weld Testing”, OS-F101, Submarine Pipeline

Systems, January 2000.
API Std. 1104 – “Welding of Pipeline and Related Facilities”.
3.0 APPROVED AGENCIES
Following agencies for Automatic Ultrasonic Testing (AUT) are acceptable:

a) RTD Quality Services, Rotterdam, Netherlands
b) SHAW Pipeline Services, Canada
c) WELDSONIX, USA
d) UT Quality, Canada
e) SCI, Spain
f) SIEVERT Group of Cos., India
In case bidder proposes to employ any other agency, the proposed agency shall meet the
qualification criteria listed below and shall submit necessary documentation. The detailed
system description and procedure shall be submitted for COMPANY evaluation/ approval.
Automatic Ultrasonic Testing systems and agencies who have proven track record and have
done a single project of diameter 20” or above and minimum length of 50 km and also have
inspected a cumulative length of 500 km or above on large diameter Pipe lines in the last ten
years shall only be accepted. The agency should have been approved by the reputed inspection
agencies. The track record shall be submitted to the COMPANY for approval prior to
engagement.
4.0 AUT SYSTEM
The system shall meet and exceed the requirements of ASTM E1961-98.
The system shall provide an adequate number of examination channels to ensure the complete
volumetric examination of the weld through the thickness in one circumferential scan.
The evaluation zones should be of maximum 2.0mm height. The instrument linearity should
be such that the accuracy is within 5%.
Each examination channel should be selective for pulse-echo or through transmission mode
gate position and length for a minimum of two gates and gain.
TOFD techniques & B-scan mapping should be available to improve characterization.

Recording thresholds should be selectable to display signals between 0 and 100% of full
screen height for simple amplitude and transit time recording and it should be from 0 to 100%
for B-scan or mapping type recording of data. Two recordable signals output per gate should
be available being either analog or digital and representative of signal height and time of
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flight. Measuring distance accuracy of circumferential weld shall be within 1.0 cm from zero
(0) position.
Electronic noise shall be lower than acoustical noise in all channels for the probes and
sensitivities to be used during inspection. The signal to noise ratio for each channel during
examination shall be at least ≥ 20 dB for shear waved probes.
5.0 COUPLING
The coupling shall be obtained by using a medium suitable for the purpose. It shall be suitable
for the temperature used. No residue shall remain on the pipe surface. A method should be
employed to determine that constant coupling is achieved during examination. An examination
of the test piece with its surface wiped dry should produce a record showing an absence of the
couplant recording signal.
6.0 SEARCH UNITS
The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961-98.
7.0 CALIBRATIONS
Reference standards shall be manufactured from a section of unflawed project specific line
pipe supplied by pipeline CONTRACTOR. The agency shall then submit the reference
standard design to the COMPANY before manufacturing. No design changes in the reference
standard shall be made without the prior approval. Annexure A3 of the standard ASTM
E1961-98 provides an example for minimum requirements for reference standards.
The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E 1961-
98. Static and Dynamic calibration shall be done and the approved procedure shall clearly
state the gain setting fixed for each channel.
The reference standard should be used to verify the scanning sensitivity at the start of each
shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds.
A re-calibration shall be carried out if

- The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
- The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration.
- After a weld repair
- After equipment breakdown
In case the calibration differs from the initial setting, outside the given tolerances, the
applicable probe(s) and coupling shall be checked. If the calibration has to be changed, the
welds before this calibration upto the previous calibration will be re-examined.
The reference standard design for calibration shall be approved separately. The procedure for
calibration and verification shall be same as given above.
8.0 PROCEDURE
A detailed Automated Ultrasonic examination procedure shall be prepared and qualified for
each wall thickness and joint geometry to be examined prior to the start of any NDT work.
Repair procedure shall be separately qualified for each joint geometry. All the requirements of
ASTM E1961-98 should be met. The procedure as a minimum shall include the following:
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- Functional description of equipment

- Reference standards and guidelines controlling equipment maintenance
- Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics, Hard
& Software for recording processing, Display presentation and storage of inspection
data
- Transducer configuration(s), characteristics types coverage.
- Number of examination zones for each wall thickness to be examined.
- Gate settings
- Equipment settings
- Description of calibration blocks including type, size and location of calibration
reflectors, a) calibration intervals, b) calibration records
- Static and dynamic calibration procedure
- Identification of inspection starting point scanning direction and indication of length
inspected
- Method for scanner alignment and maintenance of alignment
- Allowed temperature range
- Couplant coupling and coupling control and channels provided to indicate lack of
coupling and method to ensure constant coupling
- Transducer and over all functional checks
- Height and length sizing methodology
- Surface condition and preparation
- Description of inspection work
- Acceptance criteria and instructions for reporting including example of recorder
chart and form to be used.
- A table indicating corresponding channel no., probe, type, location of reflector,
probe coupling etc.
8.1 Setting of inspection gates
8.1.1 Pulse-echo and tandem channels
With each transducer positioned for the peak signal response from the calibration reflector the
detection gates are to be set. The gate shall start 2-6mm (allowance for width of heat affected
zone) before the theoretical weld bevel preparation. The gate ends shall be after the theoretical
weld centerline. All gates will be programmed to record amplitude and/or transit distance
information. The length of the transit distance in the root channel will be extended to enable
root penetration registration.
8.1.2 Mapping channels
The mapping gates in the body of the weld shall start 2-6mm (allowance for width of heat
affected zone) before the theoretical weld bevel preparation. The gate length will be extended
to enable cap reinforcement registration. The mapping gates in the root will be set identical to
the pulse-echo transit distance channels to enable the registration of the root penetration.
8.1.3 TOFD channel
The TOFD gate start will be set 1 μSec before the arrival of the lateral wave and should extend
up to the first back wall echo to achieve full cover of wall thickness.
Note: The gate settings may be altered if geometry indications dictate.
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8.1.4 Sensitivity settings
With each transducer positioned for the peak signal response from the calibration reflector
(flat bottom holes), the detection gates are to be set. In this position, the probe holder is fixed
to the probe frame. The equipment sensitivity (echo amplitude) for all inspection channels
shall be set at 80% Full Screen Height (FSH).
Mapping channels in the body of the weld will be used to detect the presence of porosity and
in addition to identify the position of the weld cap reinforcement for pattern recognition
purpose. The sensitivity as a minimum is equal to the related pulse- echo channels, increased
with additional gain to ensure proper detection.
Mapping channels in the root will be used to identify the position of the root penetration for
pattern recognition purpose. The sensitivity as a minimum shall be equal to the related pulse-
echo channels, increased with additional gain to ensure proper detection.
The lateral wave of the TOFD channel sensitivity is set at 80% FSH.
9.0 TRAINING AND QUALIFICATION
1. All Inspectors’ of the COMPANY (Owner) shall be imparted training at the

CONTRACTOR’s cost. The inspector shall be provided complete awareness and
knowledge regarding the equipment, limitations, capabilities complete range, method of
operation, calibration, scanning, including development of suitable procedure, training on
variables effecting the system performance and interpretation of results.
2. The Ultrasonic lead operator performing the examination shall be qualified in accordance
with the COMPANY’s written practice and in accordance with ASNT Practice SNT-TC-
1A and EN 473 Level II. He should have experience in multichannel UT equipment and be
trained in using mechanized UT manipulators.
10.0 FIELD EXAMINATIONS AND REPORTING
All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a
minimum.
11.0 INTERPRETATION OF RESULTS

11.1 General
With the transit distance measurements and with the information from the mapping and TOFD
channels visible on the result presentation, indications shall be judged whether they are from
the weld geometry or from the defects. The coupling channels will check for coupling loss; in
case of coupling loss, a re-scan shall be carried out.
11.2 Inspection result
The inspection result should be evaluated and/or reported as follows:

Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below. This
shall be performed in parallel and rejection against either of these criteria shall be cause for
rejection of the weld. The exceptions to this are described in the following notes:
1. All indications in the pulse echo channels should be evaluated which exceed the
threshold level of 20% FSH.
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2. Defect length shall be measured for the pulse-echo channels from the point where the
signal exceeds 20% FSH to the point the signal falls below. The largest height assessed
with TOFD or the greatest measured amplitude with pulse-echo shall be assumed to
apply over the whole defect length.
3. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw diffraction
tips cannot be separately distinguished, no measurement can be made to determine the
defect height. In this case, the signal from the pulse-echo channels will be solely used to
determine that particular area of the scan.
4. Defects shall be assessed for interaction as follows:
a) Horizontal interaction
If the distance between two adjacent defects is less than the length of the smaller of
the two defects, then the defect shall be treated as a single defect.
b) Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the distance between
the two adjacent defects is less then the height of the shorter of the two defects, than
the defect shall be treated as a single defect. Where the individual defects cannot be
resolved by TOFD for the vertical interaction, then the defects are assumed to
interact and shall be treated as a single defect.
5. The maximum allowable accumulated defect length shall be as per the criteria given in
welding specification para 12.5.1.
12.0 ACCEPTANCE CRITERIA
Weld quality shall be judged on the basis of the acceptability criteria mentioned in Para 12.5.1
of welding specification.
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ANNEXURE-4
RADIOGRAPHY
1.0 SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the
main pipeline.
The welded joints shall include the following:
i) Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
ii) Welds for installation of block valves, insulating joints and other appurtenances and tie-
ins.
iii) Welds at scraper launching and receiving barrels.
iv) Terminal Piping.
2.0 APPLICABLE STANDARDS

This specification shall apply in conjunction with the following (all latest editions):
i) API 1104, Standard for welding Pipelines and Related Facilities
ii) ANSI B 31.8, Code for Gas Transmission and Distribution Piping Systems.
iii) ANSI B 31.4, Code for Transportation System for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and Alcohols.
iv) ASTM E 94, Recommended practice for Radiographic Testing
v) ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing
v) The American Society for Nondestructive Testing. Recommended Practice No. SNT-
TC-1A Supplement A.
3.0 PROCEDURE
3.1 The Radiography examination procedure to be adopted shall be submitted by the
CONTRACTOR as per Exhibit - F.
3.2 The procedure of Radiography examination shall be qualified to the entire satisfaction of
COMPANY prior to use. It shall include but not be limited to the following requirements:
i) Lead foil intensifying screens, at the rear of the film shall be used for all exposures.
ii) Type 2 and 3 films as per ASTM E-94 shall be used.
iii) 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.
iv) 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.
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3.5 All the girth welds of mainline shall be subjected to 100% Radiography examination. The
CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved format.
The details of the radiographs along with the joint identification number shall be duly entered
in a register and signed by the CONTRACTOR and submitted to the COMPANY for
approval.
3.6 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each exposure
shall not exceed the values given. The minimum film overlap, in such cases, shall be 40mm.
The ellipse exposure technique may be used on nominal pipe sizes of 2 inch and smaller
provided that the source of film distance used is a minimum of 12 inch.
3.7 Three (3) copies of each acceptable Radiography procedure (as per Exhibit-F) and three (3)
copies of Radiography qualification records, shall be supplied to COMPANY. One set of the
qualifying radiographs on the job shall be kept by the CONTRACTOR's authorized
representative to be used as a standard for the quality of production Radiography during the
job. The other two sets shall be retained by COMPANY for its permanent record.
3.8 Three (3) copies of the exposure charts relating to material thickness, kilo voltage, source to
film distance and exposure time shall also be made available to COMPANY by the
CONTRACTOR.
3.9 The CONTRACTOR shall record for each radiograph on a daily basis (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds meet the
specified acceptance standards, and (4) the nature and approximate location of unacceptable
defects observed to correlate to a particular butt weld and welder on piping drawing and
pipeline alignment drawing.
3.10 Each day's production of processed radiographs shall be properly packaged separately,
identified by (1) date, (2) radiography unit, (3) job locations, (4) starting and ending progress
survey stations, and (5) shall include original and three (3) copies of the daily radiography
record. The package shall be submitted to the COMPANY daily when possible, but in no
event later than noon of the following day.
3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room with
controlled temperature, film viewer etc. to enable the COMPANY to examine the radiographs.
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.
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5.0 LEVEL OF QUALITY

The quality level of Radiography sensitivity required for Radiography inspection shall be at
least equivalent to the values in FIG.5.
6.0 PENETRAMETERS
6.1 The Image Quality Indicator (IQI) shall be used for the qualification of the welding procedure
and during normal line production. Radiography sensitivity shall be measured with the wire
image quality indicator (Penetrameter). The Penetrameter shall be selected according to DIN-
54109 or ISO-1027. For radiographs made with the source on the outside, a Penetrameter
shall be placed on each side of the film with the smaller wire of the Penetrameter turned
towards the end of the film itself. When a complete weld is radiographed in a single exposure
using a source inside the piping, four pentrameters approximately equally spaced around the
circumference shall be used. During the procedure qualification, IQI shall be placed both on
the source side and on the film side. The sensitivity obtained with IQI on the source side shall
not be less than the values shown in FIG.5 of this specification.
The sensitivity limit may be considered to have been reached when 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.
7.0 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.
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.
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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.
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for providing the
radiographic equipment, radiographic films and all the accessories for carrying out the
Radiography examination for satisfactory and timely completion of the job.
12.2 For carrying out the mainline Radiography examination, the CONTRACTOR shall be
equipped with suitable mobile/stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and suitably
controlled to allow viewing film densities up to 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 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.
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16.0 FIRST AID AND INDUSTRIAL INJURIES

16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of sub-
contractors.
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 CONTRACTOR from the
operation of any other act or rules in force.
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Sheet 1 of 3
EXHIBIT - A
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

1.
2.
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EXHIBIT – A (CONTD.)
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
4
5
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 used :
Visual Inspection Results :
1)
2)
3)
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EXHIBIT – A (CONTD.)
Sheet 3 of 3
Macro Test Results :
Fracture Test Results :
Remarks :
F. Other Test Results :
1. Transverse tensile test :
In combination with :
Base material used :
Position of welding :
Preheat temperature :
Post weld heat treatment :
Radiography :
Identification No. U.T.S. Fracture in Remarks
2. Guided Bend Test :

Position Identification Root, Face or Side Bend Rema
No. rks
1
2
3
4
5
G. Any other tests :
H. Conclusions :
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PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (EIL/OWNER)
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Sheet 1 of 1
EXHIBIT - B
STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION

Name of the Heat-Treater :
Name of the Project : Specification Reference No.:
1. General Detail: 2. Furnace Details:

Name of the Equipment: Type of Heating : Gas/Oil/Elect.
Name of the Assembly/Part: Res./Induction Type of Heating :
Drawing No: Capacity (Size) :
Material: Maximum Temp.( C) :
Method of temp. Measurement
Atmosphere Control :
3. Heat Treatment Cycle Details :

Charging Temp. C
Rate of heating, C/Hr
Soaking Temp. C
Soaking Time, hrs.
Rate of Cooling, C/Hr.
Mode of Cooling
4. Other Details, if any :
Notes:
The following documents shall be furnished along with the specifications :
i) Material test certificates
ii) Assembly/Part Drawing.
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PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (EIL/OWNER)
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Sheet 1 of 3
EXHIBIT - C
EXAMPLE OF RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST
Project/Contract Contractor
Pipe and fitting material
Process
Outside diameter
Pipe thickness
Joint design (Sketch attached)
Make and Diameter Current Voltage
type of
filler
metal
Root
Second run
Other runs
Other electrical characteristics a.c/d.c Electrode negative/Positive
Shielding gas
Type of mixture
Flow
Shielding flux
Position
Direction of welding :
Root : Vertical up*/ Vertical down
Second run : Vertical up*/ Vertical down
Other runs : Vertical up*/ Vertical down
Number of welders :
Root
Second run
Other runs
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EXHIBIT – C (CONTD.)
Sheet 2 of 3
Time lapse between commencement of second

run and commencement of other runs
Minimum number of runs before joint allowed
to cool
Maximum time between commencement and
completion of weld
Type of line-up clamp
Removal of clamp after run
Lowering off after run
Cleaning
Preheating
Minimum temperature C Ambient temperature C
Type of heater to be used
Interpass temperature
Minimum C Maximum C
Post weld heat treatment
Speed of travel
Test Results
State acceptable ‘non-acceptable (with
reasons) or give numerical results
Non-destructive tests
Visual
Radiograph
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EXHIBIT – C (CONTD.)
Sheet 3 of 3
Destructive tests 1 2 3 4
Transverse tensile
Tensile strength (with units)
Fracture location
Test temperature
Macro-examination
Fillet weld fracture
Hardness survey :
Type
Hardness range :
Parent metal
Heat affected zone
weld
Charpy V-notch impact tests
Specimen location and size
Notch location
Test temperature
Results (with units)
Additional test(s) and results e.g. Chemical analysis, Micro-examination, CTOD tests, Bend tests,
Nick-Break test.
The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of specification.
CONTRACTOR INSPECTOR
POSITION WITNESSED BY
Date Date
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Sheet 1 of 1
EXHIBIT - D
EXAMPLE OF RECORD FORM FOR WELDER QUALIFICATION TEST
Welder test certificate Test no.
Project/Contract Date
Contractor Inspector
Welder’s name
Address
Pipe material
Pipe thickness
Pipe outside diameter
Welding process Root
Fill and cap
Electrode/wire
Root Current Voltage
Second run Current Voltage
Fill and cap Current Voltage
Direction of travel Root: Vertical up/Vertical down*
Fill & cap: Vertical up/Vertical down*
Reason for failure

Visual
Non-destructive testing
Butt joint
Fillet weld
` Number of attempts
Comments
Accepted date/Time
SIGNED BY CONTRACTOR SIGNED BY INSPECTOR
* Delete as necessary
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Sheet 1 of 1
EXHIBIT - E
WELDER’S IDENTIFICATION CARD
Name :
Identification :
Photograph
Date of Testing :
Valid till :
Approval of Welding :
Welding Position :
Material :
Diameter :
` Diameter range approved :
Wall thickness :
Thickness range approved :
Type of welding consumables :
APPROVED BY: EMPLOYERS’SIGNATURE WITH SEAL
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Sheet 1 of 1
EXHIBIT - F
RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia & Thickness
6. Type of weld joint
7. Radiation Source (X-ray, iridium)
8. Type of equipment (External/Internal)
9. Intensifying screens and material
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation source or
specimen.
11. Exposure Geometry (Source focal spot size, object to film distance, radiation angle with
respect to weld and film).
12. Limit of film coverage
13. Film type and make
14. Exposure Conditions (ma, KV, time)
15. Processing (time temperature for development stop bath or rinse, fixation, washing, drying
etc.)
16. Density
17. Sensitivity
18. Type of penetrameter
19. Essential wire to be seen on source side:

Essential wire accepted for film side viewing:
APPROVAL OF THE COMPANY SIGNATURE OF CONTRACTOR WITH SEAL
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A286-000-06-41-WSP-01
Rev. 1
OF GIGL
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A286-000-06-41-WSP-01
Rev. 1
OF GIGL
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A286-000-06-41-WSP-01
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OF GIGL
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FIGURE 5. REQUIRED IQI SENSITIVITY SOURCE SIDE PENETRAMETER
STANDARD SPECIFICATION STANDARD SPECIFICATION No.
a*zre? ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
INDIA LIMITED
sfe-e09Teg IA GoN ol Ind. Under131(.91 PLUG VALVES (ONSHORE) Page 1 of 13
WFT cuzciA
* RIR
1 111 ch I11 c l
STANDARD SPECIFICATION
FOR PIPELINE
LUBRICATED PLUG VALVES
(ONSHORE)
REVISED & REISSUED AS STANDARD

4 01.03.12 SPECIFICATION
REVISED & REISSUED AS STANDARD VM AS
3 22-11-06 MKM
SPECIFICATION
REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
2 19-10-01 SPECIFICATION
REVISED & REISSUED AS STANDARD LD ASr VC AS
0 05-07-89 ISSUED AS STANDARD SPECIFICATION MK GD RKD/SA
Standards Standards
Prepared Checked Committee Bureau
Rev. Purpose Convenor Chairman
Date by by
No
Approved by
Format No. 8-00-0001-Ft Rev. 0 Copyright El L - All rights reserved

aleTaENGNEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
lagleg W INDIA LIMITED PLUG VALVES (ONSHORE)
(A Gov( of India Undertaking) Page 2 of 13
Abbreviations:
ASME American Society of Mechanical Engineers

ASTM American Society of Testing of Materials
BHN Brinell Hardness Number
DN Nominal Size
LC Lock Close (valve locked in full close position)
LO Lock Open (valve locked in full open position)
MSS-SP Manufacturers Standardization Society — Standard Practice
RTJ Ring Type Joint
SSPC Steel Structures Painting Council
Pipeline Engineering Standards Committee
Convenor : Mr. Vinay Mittal
Members: Mr. S.K.Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Dr. R. S. Bhatia (Piping)
Mr. R. Chaudhury (SMMS)
Mr. A. K. Chaudhary (PDD)
Mr. S. S. Lotay (Inspection)
Mr. G. K. Iyer (HO Construction)
Mr. M. P. Jain (Projects)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

lalfazitlia ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
b‘g-ia iffitegW7 INDIA LIMITED PLUG VALVES (ONSHORE)
IA Goof of loam undenaiongf Page 3 of 13
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE DOCUMENTS 4
3.0 MATERIALS 5
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS 5
5.0 INSPECTION AND TESTS 8
6.0 TEST CERTIFICATES 10
7.0 PAINTING, MARKING AND SHIPMENT 11
8.0 SPARES AND ACCESSORIES 11
9.0 DOCUMENTATION 11
Figure 4.6 SEALANT DETAILS 13
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

a
t - ') ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
5ig-r OW-G. 1W INDIA
DAUNTED
eRenieeni."13151/1 IA GOvt Of India undertaking) PLUG VALVES (ONSHORE) Page 4 of 13
1.0 SCOPE
supply of carbon steel lubricated plug valves of size DN 50 mm (2") and above and ANSI
pressure rating Class 150# thru 900# for use in onshore pipeline systems handling non-sour
hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
2.1 All valves shall be manufactured and supplied in accordance with the American Petroleum
Institute (API) Specification 6D, Twenty Third edition, April 2008 / ISO 14313:2007,
Petroleum and Natural Gas Industries — Pipeline Transportation Systems — Pipeline valves,
with additions and modifications as indicated in the following sections of this specification.
2.2 Reference has also been made in this specification to the latest edition (edition enforce at the
ASME B31.3 Process Piping.
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids.
ASME B31.8 Gas Transmission and Distribution Piping Systems.
ASME B16.5 Steel Pipe Flanges and Flanged Fittings.
ASME B 16.10 Face-To-Face and End-To-End Dimensions of Valves.
ASME B16.25 Butt-welding Ends
ASME B16.34 Valves - Flanged, Threaded and Welding Ends.
ASME B16.47 Large Diameter Steel Flanges.
API 1104 Welding Pipelines and Related Facilities.
ASME Sec VIII Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Sec IX Boiler and Pressure Vessel Code - Welding and Brazing
Qualifications
ASTM A 370 Standard Test Methods and Definitions for Mechanical

ASTM B733 Auto catalytic Nickel Phosphorous Coating on Metals.
MSS-SP-6 Standard Finishes for Contact Faces of Pipe Flanges and

Connecting-end Flanges of Valves and Fittings.
MSS-SP-44 Steel Pipe Line Flanges.
SSPC-VIS-1 Steel Structures Painting Council Visual Standard.

ttt5;
ft ENGINEERS
41/4.1 FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
11g7 02-defler INDIA UMITED PLUG VALVES (ONSHORE)
cp,
Gov! of intha Undeptaxing) Page 5 of 13
2.3 In case of conflict between the requirements of this specification, API 6D and the Codes,
Standards and Specifications referred in clause 2.2 above, the requirements of this
specification shall govern.
3.0 MATERIALS
3.1 Material for major components of the valves shall be as indicated in Valve Data Sheet. Other
components shall be as per Manufacturer's standard (suitable for the service conditions
indicated in Data Sheet) and shall be subject to approval by Company. In addition, the
material shall also meet the requirements specified hereinafter.
All process-wetted parts, metallic and non-metallic, and lubricants shall be suitable for the
service specified by the Company. Manufacturer shall confirm that all wetted parts are
suitable for treated water/seawater environment, which may be used during field testing.
3.2 Carbon steel used for the manufacture of valves shall be fully killed.
3.3 The Carbon Equivalent (CE) of valve end connections which are subject to further field
welding by Company shall not exceed 0.43 in check analysis for each heat of steel used, as
calculated by the following formula:
Mn Cr+ Mo+V Ni+Cu

CE = C + +
6 5 15
14 For valves specified to be used for Gas service or LPG service, Charpy V-Notch test on each
heat of base material shall be conducted as per API 6D, clause 7.5 for all pressure containing
parts such as body, end flanges and welding ends as well as bolting material for pressure
containing parts. Unless specified otherwise, the Charpy V-notch test shall be conducted at 0
°C. Test procedure shall conform to ASTM A 370. The average absorbed energy value of
three full sized specimens shall be 27 J. The minimum impact energy value of any one
specimen of the three specimens analysed as above, shall not be less than 22 J
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material
standard shall be complied with.
3.5 For valves specified to be used for Gas service or LPG service, Hardness test shall be carried
out as per ASTM A370 for each method of manufacture and each heat of steel used in the
manufacture of valves. A full thickness cross section shall be taken for this purpose and the
maximum hardness of the materials of valve components shall not exceed 248 HVIo.
3.6 For all such valves where Carbon Steel / S.G. Iron is used as plug material, the plug shall have
75 microns (0.003 inches) thick Electroless Nickel Plating (ENP) as per ASTM B733 with
following classification:
SC2, Type II, Class 2.
The hardness of plating shall be minimum 50 RC.
4.1 Valve design shall meet the requirements of API Specification 6D and shall be suitable for the
service conditions indicated in the Valve Data Sheet. The ASME Boiler & Pressure vessel
code, Section VIII, Division I shall be used to design the valve body. Allowable stress
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved

ISVITIe? ft ENGINEERS FOR PIPELINE LUBRICATED
Egreg ieS' INDIA UMITED
6-71-0016 Rev. 4
IA Govl of India Undertaong) PLUG VALVES (ONSHORE) Page 6 of 13
requirements shall comply the provisions of above code. In addition, corrosion allowance
indicated in valve Data Sheet shall be considered in valve design. The manufacturer shall have
valid license to use API monogram on valves manufactured as per API 6D.
4.2 Valve p attern area shall be as specified in the following table.

ANSI Pressure Rating Size Range, DN mm (inch) Pattern
50 - 100 (2 - 4) Short
Class 150 # 150 - 300 (6 - 12) Regular
350 (14) & above Venturi
50 - 100 (2 - 4) Short
Class 300 # 150 - 250 (6 - 10) Regular
50 - 250 (2 - 10) Regular
Class 600 #
50 - 250 (2 - 10) Regular
Class 900 # 300 (12) & above Venturi
4.3 The valves shall have an inherent feature to ensure that under 1 ne pressure, the line pressure
cannot cause taper locking of the plug / plug movement into the taper, i.e. valves shall be of
"pressure - balanced" design type.
4.4 Cover shall be bolted to the valve body and screwed connections are not acceptable.
4.5 Soft seats to achieve a seal between plug and body are not permitted.
4.6 All valves shall have the provision for sealant injection under full line pressure for seat and
stem seals. All sealant injection connections shall be provided with a block valve and internal
non-return valve. Valve design shall have a provision (e.g. Ball Type Check Valve/Needle
Valve) to replace the sealant injector fitting under full line pressure. Location and arrangement
of sealant injection points shall be as per Figure-4.6.
4.7 Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar
in both open and closed position.
4.8 Valve design shall ensure repair of gland packing under full line pressure.
4.9 a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt
welded as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged
body valves shall be integrally cast/forged with the body of the valve. Face to face/end
to end dimensions shall conform to API 6D. Face-to-face and end-to-end dimensions
for valve sizes not specified in API 6D shall be in accordance with ASME B 16.10.
Face-to-face and end-to-end dimensions not shown in API 6D or in ASME B 16.10
shall be as per Manufacturer Standard and shall be subject to approval by Company.
b) Flanged ends, if specified, shall have flanges as per ASME B16.5 for valve sizes upto
DN 600 mm (24") excluding DN 550 mm (22") and as per MSS-SP-44/ASME B
16.47 Series A for valve sizes DN 550 mm (22") and for DN 650 mm (26 inches) and
above. Flange face shall be either raised face or ring joint type (RTJ) as indicated in
Valve Data Sheet. Flange face finish shall be serrated or smooth as indicated in Valve
Data Sheet. In case of RTJ flanges, the groove hardness shall be minimum 140 BHN.

lfele.l a ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
grir 'Meg Ws INDIA LIMITED
PLUG VALVES (ONSHORE)
011171 eRenRanartill IA Gorl of undo Undeflakingi Page 7 of 13
c) Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe to
which the valve has to be welded shall be as indicated in the Valve Data Sheet. In case
difference exists between thickness of welding ends of valve and connecting pipe, the
welding ends of valve shall have bevel preparation as per ASME B31.4 or ASME
B31.8 as applicable.
4.10 Valves shall be provided with plug position indicator and stops of rugged construction at the
fully open and fully closed positions.
4.11 When indicated in Material Requisition, valves shall have locking devices to lock the valve
either in full open (LO) or full close (LC) position. Locking devices shall be permanently
attached to the valve operator and shall not interfere with operation of the valve.
4.12 Valves shall be suitable for either buried or aboveground installation as indicated in Valve
Data Sheet.
4.13 When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions:
In case of below ground LTCS valves, Stem extension material shall be equivalent to
Stem Material.
Valves provided with stem extension shall have water proof outer casing. Length of
stem extension shall be as indicated in Valve Data Sheet. The length indicated
corresponds to the distance between centerline of the valve opening and the top of
mounting flange for valve operating device (gear operator/power actuator as
applicable).
Seat sealant injection lines shall be extended and terminated adjacent to the valve
operator by means of suitable piping anchored to the valve body/ stem housing. The
pipe used shall be API 5L Gr. B / ASTM A 106 Gr. B, with Sch. 160 for sizes 0.5 to
0.75 inch and Sch. 80 for sizes 1.0 to 1.5 inch. Fittings shall be ASTM A105/ASTM
A234 Gr. WPB, Socket welded ANSI class 6000.
Stem extension and stem housing design shall be such that the complete assembly will
form a rigid unit giving positive drive under all conditions with no possibility of free
movement between valve body, stem extension or its operator.
e) Outer casing of stem extension shall have %"" or 1/2" NPT plugs at the top and bottom,
for draining and filling with oil to prevent internal corrosion.
4.14 Operating Devices
Valves shall have a power actuator or manual operator as indicated in the Valve Data
Sheet. In case of manual operator, valve sizes DN 100 mm (4") shall be wrench
operated and valve sizes ^ DN 150 mm (6") shall be gear operated. Each wrench-
operated valve shall be supplied with wrench. Valve design shall be such that damage
due to malfunctioning of the operator or its controls will only occur in the operator
gear train or power cylinder and that damaged parts can be replaced without the valve
cover being removed.
The power actuator shall be in accordance with the Company specification issued for
the purpose and as indicated in the Valve and Actuator Data Sheet. Operating time
shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to
full close to full open/full open to full close under maximum differential pressure
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved

lafrneTa ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
ui falareg W INDIA LIMITED PLUG VALVES (ONSHORE)
imR"mww") IA GEM of Ma undertaking) Page 8 of 13
corresponding to the valve rating. For actuator valves, the actuator rated torque output
shall be at least 1.25 times the break torque required to operate the valve under
maximum differential pressure corresponding to the valve class rating.
For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, the total
force required to operate the valve does not exceed 350N. However. failing to meet
above requirement , vendor shall offer Gear operated valves. Manufacturer shall also
indicate the number of turns of hand wheel in case of gear operators (along with their
offer) required for operating the valve from MI open to full close position. The
number of turns shall not exceed 200 for valve sizes up-to 24" and 400 for valve sizes
above 24".
Direction of operation of hand wheel or wrench shall be in clock-wise direction while

closing the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully
encased in water proof/splash proof enclosure and shall be filled with suitable grease.
provisions of ASME Section IX. The procedure qualification shall also include impact test and
4.16 Repair by welding is not permitted for fabricated and forged body valves. However repair by
welding as per ASME B16.34 is permitted for cast body valves. Such repairs shall be carried
out at casting supplier's care only. Repair shall be carried out before any heat treatment of
casting is done. Repair welding procedure qualification shall also include impact test and
requirements as specified therein. Heat treatment and radiography shall be repeated after the
weld repair.
4.17 The tolerance on internal diameter and out of roundness at the ends for welded ends valves
shall be as per connected pipe specification as indicated in the Valve Data Sheet.
4.18 No casting is permitted for stem and stem extension material of all valves. Valve stem shall be
capable of withstanding the maximum operating torque required to operate the valve against
the maximum differential pressure corresponding to applicable class rating. The combined
stress shall not exceed the maximum allowable stresses specified in ASME section VIII,
Division 1. For Power Actuated Valves, the valve stem shall be designed for maximum output
torque of the selected power actuator (including gear box, if any) at the valve stem.
4.19 Valves of nominal valve size DN 200 mm (8") & above shall be equipped with lifting lugs.
Tapped holes and eyebolts shall not be used for lifting lugs.
4.20 Wherever specified for the parts of valve in valve datasheets, minimum thickness of stelliting
shall be 1.6 mm.
specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests
shall be, but not limited to, the following:

Prazie? fit ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
-Lite'el INDIA LIMITED PLUG VALVES (ONSHORE)
Gov( o/ India Undertaking) Page 9 of 13
5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves shall be
free from any strikes, gouges and other detrimental defects. The surfaces shall be thoroughly
5.1.2 Dimensional check on all valves shall be carried out as per the Company approved drawings.
5.1.3 Chemical composition and mechanical properties shall be checked as per this specification
and relevant material standards, for each heat of steel used.
5.1.4 Non destructive examination of individual valve material and components consisting of but
not limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer.
Body castings of valves shall be radiographically examined as per ASME B16.34.

Procedure and acceptance criteria shall be as per ASME 816.34. The extent of
radiography shall be as follows:
Pressure Class Rating Valve Size Extent of Radiography

ANSI 150 # Class < DN 600 mm (24") Nil
> DN 650 mm (26") 100%
ANSI 300 # Class < DN 400 mm (16") Nil
> DN 450 mm (18") 100%
ANSI 600 # Class and above All sizes 100%
Radiography shall be performed after the final heat treatment also.
All castings shall be wet magnetic particle inspected 100% of the internal surfaces.
All valves made by forgings shall be ultrasonically examined in accordance with the
procedure and acceptance standard of Annexure E of ASME B16.34.
5.1.5 Areas, which in Company's opinion cannot be inspected by radiographic methods, shall be
checked by ultrasonic or magnetic particle methods and acceptance criteria shall be as per
ASME Sec. VIII, Division 1, Appendix 12 and Appendix 6 respectively.
5.1.6 a) Weld ends of all cast valves subject to welding in field shall be 100 %
radiographically examined and acceptance criteria shall be as per ASME B16.34.
After final machining, all bevel surfaces shall be inspected by dye penetrant or wet
magnetic particle methods. All defects longer than 6.35 mm are rejected, as are the
defects between 6.35 mm and 1.59 mm that are separated by a distance less than 50
times their greatest length. Rejectable defects must be removed. Weld repair of bevel
surface is not permitted.
All finished wrought weld ends subjects to welding in field shall be 100 percent
ultrasonically tested for lamination type defects for a distance of 50 mm from the end.
Laminations shall not be acceptable.
5.1.7 All valves shall be tested in compliance with the requirements of API 6D. The sealant lines
shall be either included in the hydrostatic shell test or tested independently. Test pressure shall
be held for at least 30 minutes for both Shell & Seat test. No leakage is permissible during
hydrostatic testing.

ISifiRaeL
ie ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
, omegas
ai
mat INDI A LIMITED PLUG VALVES (ONSHORE)
IA Gov/ on inrla unaenakingi Page 10 of 13
5.1.9 A supplementary air seat test as per API 6D (Appendix C, Para C.3.3 Type II) shall be carried
out for all valves. No leakage is allowed. Test pressure shall be held for at least 15 minutes.
5.1.8 Valves shall be subjected to Operational Torque Test as per API 6D (Appendix , Para C.6)
under hydraulic pressure equal to maximum differential pressure corresponding to the valve
rating. For manually operated valves, it shall be established that the force required to operate
the valve does not exceed the requirements stated in section 4.14(c) of this specification.
5.1.9 Power actuated valves shall be tested after assembly of the valve and actuator, at the valve
Manufacturer's works. At least five Open-Close-Open cycles without internal pressure and
five Open-Close-Open cycles with maximum differential pressure corresponding to valve
rating shall be performed on the valve actuator assembly. The time for full open to full close
shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the
opening and closing time is within the limits stated in Valve data sheet.
Hand operator provided on the actuator shall also be checked after the cyclic testing, for
satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the
same size, rating and actuator model/type. In case the tests do not meet the requirements,
retesting/rejection of the lot shall be decided by purchaser's Inspector.
clause 5.1 above at Manufacturer's works prior to shipment. Manufacturer shall give
reasonable access and facilities required for inspection to the Company's inspector. Company
reserves the right to require additional testing at any time to confirm or further investigate a
suspected fault. The cost incurred shall be to Manufacturer's account.
In no case shall any action of Company or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves.
Inspection and tests performed/witnessed by the Company's inspector shall in no way relieve
the Manufacturer's obligation to perform the required inspection and tests.
Mill test certificates relevant to the chemical analysis and mechanical properties of the
materials used for the valve construction as per the relevant standards.
Test certificates of hydrostatic and pneumatic tests complete with records of timing
and pressure of each test.
Test reports of radiography and ultrasonic inspection.
Test report on operation of valves conforming to clause 5.1.8 and 5.1.9 of this
specification.
e) All other test reports and certificates as required by API 6D and this specification.
those valves which have been certified by Company's Inspector shall be dispatched from
Manufacturer's works.

OWE? ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
sigrirfitareG INDIA LIMITED
Govt al Inch. Undenak,g) PLUG VALVES (ONSHORE) Page 11 of 13
7.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot
SSPC-VIS-1". For the valves to be installed underground, when indicated in Valve Data
Sheet, the external surfaces of buried portion of the valve shall be painted with three coats of
suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns. For coastal
area, painting shall be suitable for highly corrosive environment.
7.2 All valves shall be marked as per API 6D. The units of marking shall be metric except
nominal diameter, which shall be in inches.
7.3 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces,
securely attached to the valves. Bevel ends shall be protected with metallic or high impact
7.4 All sealant lines and other cavities of the valve shall be filled with sealant before shipment.
7.5 Packaging and shipping instructions shall be as per API 6D.
7.6 On packages, the following shall be marked legibly with suitable marking ink:
Order Number
Manufacturer's Name
Valve size and rating
Tag Number.
e) Serial Number
8.1 Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning and supply of such spares shall be included in the price
quoted by Manufacturer.
8.2 Manufacturer shall famish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves and price for such spares shall be quoted
separately.
9.0 DOCUMENTATION

a) General arrangement/ Sectional drawing. Number of turns for Gear Operated valves
shall be indicated in the GA or shall be furnished separately.

IfilWrZle?
ENGINEERS
st
gar ialegver INDIA UNITED
FOR PIPELINE LUBRICATED
PLUG VALVES (ONSHORE)
6-71-0016 Rev. 4
Page 12 of 13
Reference list of similar plug valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating,
service etc.
Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque.
Copy of valid API 6D Certificate.
Copy of Fire Safe test certificate of qualifying valve as per API 6FA carried out in last
10 years shall be furnished.
e) List of recommended spares required during start-up and commissioning & 2 years of
normal operation and maintenance.
and specifications for Company's approval:
Detailed sectional drawings showing all parts with reference numbers and materials
specification.
Assembly drawings with overall dimensions and features. Drawing shall also indicate
the number of turns of hand wheel (in case of gear operators) required for operating
the valve from full open to full close position and the painting scheme.
Manufacture of valves shall commence only after approval of the above documents. Once, the
approval has been given by Company, any changes in design, material and method of
manufacture shall be notified to Company whose approval in writing of all changes shall be
obtained before the valve is manufactured.
9.3 Within 30 days from the approval date, Manufacturer shall submit to Company the approved
drawings, documents and specifications as listed in clause 9.2 above.
9.4 Prior to shipment, Manufacturer shall submit to Company, the following:
Test certificates as listed in clause 6.0 of this specification.
Manual for installation, erection, maintenance and operation instructions including a

list of recommended spares for the valves.

aa-ade ENGINEERS FOR PIPELINE LUBRICATED 6-71-0016 Rev. 4
EategNifr INDIALIMITED
PLUG VALVES (ONSHORE) Page 13 of 13
UNDER GROUND
INSTALLATION
350
SEALANT
/INJECTION
GROUND
LEVEL
ABOVE GROUND
INSTALLATION SEALANT INJECTION
LINES
SEALANT
INJECTION
FIGURE-4.6

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ala ENGINEERS
g g FLANGES & WELDED FITTINGS
li LB klie WV INDIA LIMITED (SIZE DN 450 mm (18") AND ABOVE)
Gat o4 Mula Untlettycno
6-71-0023 Rev. 4
Page 1 of 8
itkciWki utz4 44-4 rthfaiti feR

Trrw fear
(tit pt alto 450 11:1111 (18") Vert ZITO
FOR
FLANGES & WELDED FITTINGS
(SIZE DN 450 mm (18") AND ABOVE)
REVISED & REISSUED AS STANDARD SKJ VM DM

MKM SK AS Ye
REVISED 8 REISSUED AS STANDARD MKM KKS SJ GRR
REVISED 8 REISSUED AS STANDARD PKM ASr VC AS
0 15-01-90 ISSUED AS STANDARD SPECIFICATION SK RKD SA
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

laitERTMENGNEERS
Ogzg laIiikalir FLANGES & WELDED FITTINGS 6-71-0023 Rev. 4
WA LIMITED
,A so„ (SIZE DN 450 mm (18") AND ABOVE) Page 2 of 8
Abbreviations:
API : American Petroleum Institute

ASTM : American Society of Testing of Materials
BHN : Brinell Hardness Number
CE : Carbon Equivalent
DN Nominal Diameter
HAZ : Heat Affected Zone
LPG : Liquefied Petroleum Gas
LTCS : Low Temperature Carbon Steel
MSS-SP : Manufacturers Standardization Society — Standard Practice
RTJ : Ring Type Joint
SSPC : Steel Structures Painting Council

Members : Mr. S.K. Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal

ISIftne7 tak ENGINEERS FLANGES & WELDED FITTINGS 6-71-0023 Rev. 4
ILaar efaag VW INDIA LIMITED (SIZE DN 450 mm (18") AND ABOVE)
(A GoA of Inaa Undfl Mg ) Page 3 of 8
CONTENTS
1.0 SCOPE 4
3.0 MANUFACTURER'S QUALIFICATION 5
4.0 MATERIALS 5
5.0 DESIGN AND MANUFACTURE 5
9.0 DOCUMENTATION 8

dab ENGINEERS FLANGES & WELDED FITTINGS 6-71-0023 Rev. 4
sigar klieg We INDIA LIMITED
i.GeN (SIZE DN 450 mm (18") AND ABOVE)
of Ina. UncliS9) Page 4 of 8
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture and supply
of following carbon steel flanges and fittings of size DN 450 mm (18") and above to be
installed in onshore pipeline systems handling non-sour hydrocarbons in liquid or gaseous
phase including Liquefied Petroleum Gas (LPG):
Flanges such as weld neck flanges, blind flanges, spectacle blinds, spacers & blinds, etc.
Welded fittings such as tees, elbows, reducers, caps, outlets etc.
of issue of enquiry) of the following Codes, Standards and Specifications.
ASME B31.3 - Process Piping

and Other Liquids
ASME B31.8 - Gas Transmission and Distribution Piping Systems
ASME B16.5 - Pipe Flanges and Flanged Fittings
e) ASME B16.9 - Factory Made Wrought Steel Butt Welding Fittings
0 ASME B16.25 - Butt-welding Ends
ASME B16.47 - Large Diameter Steel Flanges
ASME B 16.48 - Steel Line Blanks
API 1104 - Specification for Welding Pipeline and Related Facilities
Pressure Vessels
k) ASME Sec IX - Qualification Standard for Welding and Brazing Procedures,

Welders, Brazers and Welding and Brazing Operators
1) ASTM A 370 - Standard Test Methods and Definitions for Mechanical

Testing of Steel Products
MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges and

Unions
MSS-SP-44 Steel Pipeline Flanges
MSS-SP-75 Specification for High Test Wrought Welded Fittings
MSS-SP-97 Forged Carbon Steel Branch Outlet Fittings- Socket Welding,

Threaded and Butt Welding Ends
In case of conflict between the requirements of this specification and the Codes, Standards and
Specifications referred above, the requirements of this specification shall govern.

01002-ei talk ENCINEERS FLANGES & WELDED FITTINGS 6-71-0023 Rev. 4
sigar tifAtgiet, INDIA LIMITED (SIZE DN 450 mm (18") AND ABOVE)
(A C.a.! of indu UndenaXnqi Page 5 of 8
3.0 MANUFACTURER'S QUALIFICATION
Manufacturer who intends bidding for fittings must possess the records of a successful proof
test in accordance with the provisions of ASME B16.9/MSS-SP-75, as applicable. These
records shall be submitted at the time of bidding qualifying the entire range of fittings offered.
4.0 MATERIAL
4.1 The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed. Material
for flanges and fittings shall comply with the material standards indicated in the Material/
Purchase Requisition. In addition, the material shall also meet the requirements specified
hereinafter.
4.2 Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the
following formula:
Mn Cr+ Mo+V Ni+Cu

CE=C+ +
6 5 15
4.3 For flanges and fittings specified to be used for Gas service or LPG service, Charpy V-notch
test shall be conducted on each heat of steel used. Unless specified otherwise, the Charpy V-
notch test shall be conducted at 0° C in accordance with the impact test provisions of ASTM
A 370 for flanges and MSS-SP-75 for all fittings. Results of charpy test shall be recorded
The average absorbed impact energy values of three full-sized specimens shall be 27 joules.
The minimum impact energy value of any one specimen of the three specimens analysed as
above, shall not be less than 22 Joules.
When Low Temperature Carbon Steel (LTCS) materials are specified in Purchase Requisition
for flanges and fittings, the Charpy V-notch test requirements of applicable material standard
shall be complied with.
4.4 For flanges and fittings specified to be used for Gas service or LPG service, Hardness test
shall be carried out as per ASTM A 370 for each heat of steel used. A full thickness cross
section shall be taken for this purpose and the maximum hardness of base metal, weld metal
and HAZ shall not exceed 248 HVIo.
Hardness testing shall cover at least 10% per item, per size, per heat, per manufacturing
method. The hardness shall be recorded in the test reports.
4.5 In case of RTJ (Ring Type Joint) flanges, the groove hardness shall be minimum 140 BHN.
Ring Joint flanges shall have octagonal section of Ring Joint.
5.0 DESIGN AND MANUFACTURE
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the requirements of
ASME B16.5 upto sizes DN 600 mm (24") excluding DN 550 mm (22"), and MSS-SP-44 for
sizes DN 550 mm (22") and ASME B 16.47 (Series A) for sizes DN 650 mm (26") and above.
5.2 Spectacle blind and spacer & blind shall conform to the requirements of ASME B 16.48 upto
sizes DN 600 mm (24"). For sizes DN 650 mm (26") and above, spectacle blind and spacer &
blind shall conform to Manufacturer's standard. For sizes upto DN 600 mm (24") handle
projection dimensions of spacers & blinds shall be as per EIL Std 7 44 0166. For sizes above
DN 600 mm (24") handle projection shall be such that both the holes (hole for lifting lug and

larazreift ENGINEERS FLANGES & WELDED FITTINGS 6-71-0023 Rev. 4
0151-ag 'S INDIA LIMITED (SIZE DN 450 mm (18") AND ABOVE)
i..
e. of Inaa Undertt191 Page 6 of 8
the hole for identification as spacer) are minimum 75 mm outside the outside diameter of the
corresponding weld neck end flange of ASME B-16.47 series A. Ring joint Fig.8 flanges,
spacers & blinds shall be female type only.
5.3 Type, face and face finish of flanges shall be as specified in Material/Purchase Requisition.
5.4 Fittings such as tees, elbows, reducers, etc. shall be either welded or seamless type. All welded
fittings shall be subjected to heat treatment. All fittings (except weldolets) shall comply with
the requirements of MSS-SP-75. Fittings such as weldolets etc. shall be manufactured in
accordance with MSS-SP-97. Welded pipes used for fittings shall be LSAW type only.
5.5 For reducing butt weld fittings having different wall thickness at each end, the greater
thickness of fitting shall be employed and inside bore at each end shall be matched with the
specified inside diameter.
5.6 Tees shall be manufactured by forging or extrusion method. Stub-in or pipe to pipe connection
shall not be used in the manufacture of tees. The longitudinal weld seam shall be kept at 90°
from the extrusion. Fittings shall not have any circumferential weld joint.
5.7 All butt weld ends shall be bevelled as per ASME B16.5/MSS-SP-44/ASME B16.47 as
applicable for flanges and MSS-SP-75/MSS-SP-97 as applicable for fittings.
5.8 Inside weld projection for welded fittings shall not exceed 1.6 mm. The reinforcement of
inside weld seam shall be removed for a distance of 100 mm from each end of welded fittings.
5.9 All welds shall be made by welders and welding procedures qualified in accordance with
provisions of ASME Sec. IX. The procedure qualification shall include Charpy V-notch test
for weld/heat affected zone and hardness test in accordance with clause 4.3 and 4.4 of this
specification respectively.
5.10 Repair by welding on flanges and parent metal of fittings is not permitted. Repair of weld
seam by welding shall be carried out by welders and welding procedures duly qualified as per
ASME Section IX and records for each repair shall be maintained. Repair welding procedure
qualification shall include all tests, which are applicable for regular production welding
procedure qualification. All heat treatment and radiography shall be repeated after the repair.
5.11 The tolerance on internal diameter and out of roundness at the ends for welded fittings shall be
as per connected pipe specification / as indicated in Material Requisition.
6.1 The Manufacturer shall perform all inspections and tests as per the requirement of this
specification and the relevant codes, prior to shipment at his works. Such inspections and tests
shall be, but not limited to the following:
6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the
flanges and fittings shall be free from any strikes, gauges and other detrimental defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5/MSS-SP-
44/ASME B16.47 (Series A) as applicable for flanges, ASME B 16.48 for spacers and blinds
and ASME B16.9/MSS-SP-75/MSS-SP-97 as applicable for fittings and as per this
specification.
6.1.3 Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.

areTift ENGINEERS FLANGES & WELDED 6-71-0023 Rev. 4
5ftrldfflegiav WA
(. LIMITED (SIZE DN 450 mm (18") AND ABOVE)
Govt c4 Inda t}tcyOtg,
FITTINGS
Page 7 of 8
6.1.4 The non-destructive inspection shall be carried out as given below:
All butt and repair welds for welded fittings shall be examined 100 % by radiography.
Acceptance criteria shall be as be ASME B 31.4 or ASME B 31.8 as applicable and
API 1104. Radiography shall be performed after the final heat treatment.
When elbows of size > DN 450 mm (18") are manufactured, the first elbow of each
radius, diameter and wall thickness shall be ultrasonically checked for sufficient wall
thickness in areas where a minimum wall thickness is to be expected. This shall be
followed by random inspection of one out of every three elbows of the same radius,
diameter and wall thickness.
All finished wrought weld ends shall be 100% tested for lamination type defects by
ultrasonic test. Any lamination larger then 6.35 mm shall not be acceptable.
Magnetic particle or liquid penetrant examination shall be performed on cold formed

butt welding tees with extruded outlets as per applicable material standard.
e) Welds, which cannot be inspected by radiographic methods, shall be checked by

ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME
Section VIII Appendix U and Appendix VI respectively.
6.2 Purchaser's Inspector reserves the right to perform stage wise inspection and witness tests, as
indicated in clause 6.1 of this specification at Manufacturer's Works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide, without charge,
reasonable access and facilities required for inspection, to the Purchaser's Inspector.
Inspection and tests performed/witnessed by Purchaser's Inspector shall in no way relieve the
Manufacturer's obligation to perform the required inspection and tests.
Manufacturer shall furnish the following certificates:
Test certificates relevant to the chemical analysis and mechanical properties of the
materials used for manufacture of flanges and fittings as per relevant standards and
this specification.
Test Reports on radiography, ultrasonic inspection, and magnetic particle / liquid

penetrant examination.
Test reports of heat treatment carried out as per the specification.
Welding procedures and welders qualification reports.
e) Test certificate for each fitting stating that it is capable of withstanding without
leakage a test pressure, which results in a hoop stress equivalent to 100 % of the
specified minimum yield strength for the pipe with which the fitting is to be attached
without impairment of serviceability.
8.1 After all inspection and tests required have been carried out; all external surfaces shall be
thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill

laraziee ENGINEERS
k
FLANGES & WELDED FITTINGS 6-71-0023 Rev. 4
_L8 laglegvair INDIAroesus...0
LIMITED (SIZE DN 450 mm (18") AND ABOVE)
.---) GoN ° Page 8 of 8
coating for protection against corrosion during transit and storage. The coating shall be easily
removable in the field.
8.2 Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage
during transit. Metallic or high impact plastic bevel protectors shall be provided for flanges
and fittings. Flange face shall be suitably protected to avoid any damage during transit.
8.3 All flanges and fittings shall be marked as per applicable dimension/manufacturing standard.
9.0 DOCUMENTATION

of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT
document/Material Requisition.
9.1 Prior to shipment, the Manufacturer shall submit the test certificates as listed in clause 7.0 of
this specification.
9.2 All documents shall be in English Language only.

r ENGINEERS
Ofazieleh SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
tageg W INDIA L IMITED
Go„ a ma unam*.q■ (SIZE UPTO DN 400 mm (16")) Page 1 of 7
Maim Ri4 1 * fffg L
faMgr
(trwi alto 400 'PTA (16")'ff-W)
FOR
SEAMLESS FITTINGS & FLANGES
(SIZE UP TO DN 400 mm (16"))
V.` QI ;-
:i.j? (A44&/t
4 16-02-12 REVISED 8 REISSUED AS STANDARD Wer S KJ VM DM
SPECIFICATION
3 21-11-06 REVISED & REISSUED AS STANDARD MKM SK AS V C.
SPECIFICATION
2 25-10-01 REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
SPECIFICATION
1 21-09-98 REVISED & REISSUED AS STANDARD ALP ASo VC AS
SPECIFICATION
Standards Standards
Rev. Date Purpose Convenor Chairman
No by by
Approved by

,FMEumom
ERS STANDARD SPECIFICATION FOR
SEAMLESS FITTING & FLANGES
(SIZE UPTO DN 400 mm (16"))
STANDARD SPECIFICATION No.
6-71-0024 Rev. 4
Page 2 of 7
Abbreviations:

CE Carbon Equivalent
DN Nominal Diameter
LPG Liquified Petroleum Gas
LTCS Low Temperature Carbon Steel
RTJ Ring Type Joint

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Format No. 8-00.0001-F1 Rev. 0 Copyright EIL — All rights reserved

ENGINEERS SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
Itgar Ell5legieir
INDIA LIMITED
Gn Undeltalng) (SIZE UPTO DN 400 mm (16")) Page 3 of 7
CONTENTS
1.0 SCOPE 4
4.0 MATERIALS 5
5.0 DESIGN AND MANUFACTURE 5
9.0 DOCUMENTATION 7

55ftre ENGINEERS SEAMLESS FITTING & FLANGES
SEAMLESS Rev. 4
ligzirleS INDIA LIMITED (SIZE UPTO DN 400 mm (16"))
JAG., wmund..,,,, Page 4 of 7
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture and supply of
following carbon steel flanges and fittings of size upto DN 400 mm (16") to be installed in
onshore pipeline systems handling non-sour hydrocarbons in liquid or gaseous phase including
Liquefied Petroleum Gas (LPG):
Flanges such as welding neck flanges, blind flanges, spectacle blinds, spacers and
blinds etc.
Seamless fittings such as tees, elbows, reducers, caps, outlets etc.
of issue of enquiry) of the following Codes, Standards and Specifications:

and Other Liquids
ASME B31.8 - Gas Transmission and Distribution Piping Systems
ASME B16.5 - Pipe Flanges and Flanged Fittings
ASME B16.9 - Factory Made Wrought Steel Butt Welding Fittings
ASME B 16.11 - Forged Steel Fittings, Socket Welding and Threaded
ASME B 16.48 - Steel Line Blanks
API 1104 Specification for Welding Pipeline and Related Facilities
Pressure Vessels
ASME Sec IX - Qualification Standard for Welding and Brazing Procedures,

ASTM A 370 - Standard Test Methods and Definitions for Mechanical

k. MSS-SP-25 Standard Marking System for Valves, Fittings, Flanges and

Unions
1. MSS-SP-97 Forged Carbon Steel Branch Outlet Fittings — Socket

Welding, Threaded and Butt welding Ends
Specifications referred above, the requirements of this specification shall govern.
Manufacturer who intends bidding for fittings must possess the records of a successful proof
test, in accordance with the provisions of ASME B 16.9. These records shall be submitted at
the time of bidding qualifying the entire range of fittings offered.

- ENGINEERS
aairelak SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
Igzir talateg VW WA LIMITED
...g, (SIZE UPTO DN 400 mm (16")) Page 5 of 7
4.0 MATERIAL
4.1 The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed Material
for flanges and fittings shall comply with the material standard indicated in the Material/
Purchase Requisition. In addition, the material shall also meet the requirements specified
hereinafter.
4.2 Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance with the
following formula:
Mn Cr+Mo+V Ni+Cu
CE=C+ +
6 5 15
4.3 For flanges and fittings specified to be used for Gas service or LPG service, Charpy V-notch
test shall be conducted on each heat of steel used. Unless specified otherwise, the Charpy V-
notch test shall be conducted at 0° C in accordance with the impact test provisions of ASTM A
370 for flanges and fittings. Results of charpy test shall be recorded
The average absorbed impact energy values of three full-sized specimens shall be 27 joules.
The minimum impact energy value of any one specimen of the three specimens analysed as
above, shall not be less than 22 Joules.
When Low Temperature Carbon Steel (LTCS) materials are specified for flanges and fittings
in Purchase Requisition, the Charpy V-notch test requirements of applicable material standard
shall be complied with.
4.4 For flanges and fittings specified to be used for Gas service or LPG service, Hardness test
shall be carried out in accordance with ASTM A 370 for each heat of steel used. Hardness
testing shall cover at least 10% per item, per size, per heat, per manufacturing method. A full
thickness cross section shall be taken for this purpose and the maximum hardness shall not
exceed 248 HV I o. Hardness shall be recorded.
4.5 In case of RTJ (Ring Type Joint) flanges, the groove hardness shall be minimum 140 BHN.
Ring Joint flanges shall have octagonal section of Ring Joint.
5.0 DESIGN AND MANUFACTURE
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the requirements of
ASME B16.5.
5.2 Spectacle blind and spacer & blind shall conform to the requirements of ASME B 16.48. For
sizes upto DN 400 mm (16") handle projection dimensions of spacers & blinds shall be as per
EIL Std. 7-44-0166.
5.3 Butt welded end fittings such as tees, elbows, reducers, etc. shall be seamless type and shall
conform to ASME B16.9. Socket weld and screwed end fittings shall conform to ASME B
16.11 . Ring joint Fig.8 flanges, spacers & blinds shall be female type only.
5.4 Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in accordance with
MSS-SP-97.
5.5 Type, face and face finish of flanges shall be as specified in Material/ Purchase Requisition.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL-All rights reserved

zllc'
• ENGINEERS
IntlaUndadimg)
SEAMLESS FITTING & FLANGES
SEAMLESS
(SIZE UPTO DN 400 mm (16"))
6-71-0024 Rev. 4
Page 6 of 7
5.6 Flanges and fittings manufactured from bar stock are not acceptable.
5.7 All butt weld ends shall be bevelled as per ASME B 16.5/ASME B 16.9/MSS-SP-97 as
applicable.
5.8 Repair by welding on flanges and fittings are not permitted.
6.1 The Manufacturer shall perform all inspections and tests as per the requirement of this
specification and the relevant codes, prior to shipment at his works. Such inspections and tests
shall be, but not limited to the following:
6.1.1 All flanges and fittings shall be visually inspected. The internal and external surfaces of the
flanges and fittings shall be free from any strikes, gauges and other detrimental defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME B16.5 for flanges,
ASME B 16.48 for spacers and blinds and ASME B16.9/MSS -SP-97 as applicable for fittings
and as per this specification.
6.1.4 All finished wrought weld ends shall be 100% tested for lamination type defects by ultrasonic
test. Any lamination larger then 6.35 mm shall not be acceptable.
6.1.5 Magnetic particle or liquid penetrant examination shall be performed on cold formed butt
welding tees with extruded outlets as per applicable material standard.
6.2 Purchaser's Inspector reserves the right to perform stage wise inspection and witness tests, as
indicated in clause 6.1 of this specification at Manufacturer's Works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide, without charge,
reasonable access and facilities required for inspection, to the Purchaser's Inspector.
Inspection and tests performed/witnessed by Purchaser's Inspector shall in no way relieve the
materials used for manufacture of flanges and fittings as per relevant standards and
this specification.
Test Reports on non destructive testing.
c) The certificates for each fitting stating that it is capable of withstanding without
leakage a test pressure, which results in a hoop stress equivalent to 100 % of the
specified minimum yield strength for the pipe with which the fitting is to be attached
without impairment of serviceability.

larazreidah ENGINEERS SEAMLESS FITTING & FLANGES 6-71-0024 Rev. 4
ant 0151e1gWir WA LIMITED (SIZE UPTO DN 400 mm (16"))
UndeftaXnal
441P7TelAWCOISFOral lA Sp. pp,,. Page 7 of 7
thoroughly cleaned to remove grease, dust and rust and shall be applied with standard mill
coating for protection against corrosion during transit and storage. The coating shall be easily
removable in the field.
8.2 Ends of all fittings and weld neck flanges shall be suitably protected to avoid any damage
during transit. Metallic or high impact plastic bevel protectors shall be provided for fittings
and flanges. Flange face shall be suitably protected to avoid any damage during transit.
8.3 All flanges and fittings shall be marked as per applicable dimension/manufacturing standard.
9.0 DOCUMENTATION

of Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT
document/Material Requisition.
9.1 Prior to shipment, the Manufacturer shall submit test certificates as listed in clause 7.0 of this
specification.

z
Stiliazrei It ENGINEERS
sig-ael5EIftW INDIA IJMITED
FOR FLOW TEES FOR ONSHORE
6-71-0025 Rev. 4
— mew enlenel (AG'( d Undenal.g1 PIPELINES Pape 1 of 8
41§4Cyllgl1 t Z1.9.
'TRW fear
FOR
FLOW TEES
FOR
ONSHORE PIPELINES

3 21-11-06 REVISED & REISSUED AS STANDARD MKM VM AS VC.
SPECIFICATION
REVISED & REISSUED AS STANDARD SK SJ VC AS
Standards Standards
No by by
Approved by

aleVENübEEES
Ga. ns., INDIA umTED FOR FLOW TEES FOR ONSHORE 6-71-0025 Rev. 4
zlr PIPELINES
(A earl ot lode Unatia0 Page 2 of 8
Abbreviations:
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
ASTM : American Society of Testing of Materials
BHN : Brinell Hardness Number
CE : Carbon Equivalent
DN : Nominal Diameter
HAZ : Heat Affected Zone
LPG : Liquefied Petroleum Gas
LTCS : Low Temperature Carbon Steel
MSS-SP : Manufacturers Standardization Society — Standard Practice
SSPC : Steel Structures Painting Council


Mr. Raj Kumar
Mr. M. S. Gunjiyal

lagtzkqeft ENGINEERS D FOR FLOW TEES FOR ONSHORE 6-71-0025 Rev. 4
-el
ligE/legler WA LIMITE PIPELINES Page 3 of 8
CONTENTS
1.0 SCOPE 4
4.0 MATERIALS 4
6.0 INSPECTION & TESTS 6
8.0 PAINTING, MARKING & SHIPMENT 7
9.0 DOCUMENTATION 8

022:reilt ENGINEERS FOR FLOW TEES FOR ONSHORE 6-71-0025 Rev. 4
slgar iEtWeg INDIAww
LIMITED
lagioA 7WeEPAnnoWaI PIPELINES
IA Go. of India Um:MASAO Page 4 of 8
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture and supply of
carbon steel flow tees to be installed in onshore pipeline systems transporting non-sour
hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
ASME B 31.4 Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids.
ASME B 31.8 Gas Transmission and Distribution Piping Systems.
ASME B 16.9 Factory Made Wrought Steel Butt Welding Fittings.
ASME Sec VIII Boilers & Pressure Vessel Code - Rules for the
Construction of Pressure Vessels.
ASME Sec IX Boilers & Pressure Vessel Code - Welding and

Brazing Qualifications.
API 1104 Specification for Welding Pipeline and Related

Facilities.
ASTM A 370 Standard Test Methods and Definitions for

Mechanical Testing of Steel Products.
MSS-SP-53 Quality Standard for Steel Castings and Forgings for

Valves, Flanges and Fittings and Other Piping
Components-Magnetic Particle Examination Method.
i) MSS-SP-75 Specification for High Test Wrought Welding

Finings.
SSPC-VIS-1 Steel Structures Painting Council.
m) API 5L Specification for Linepipe
In case of conflict between the requirements of this specification and the codes, standards and
specifications referred above, the requirements of this specification shall govern.
3.1 Manufacturers who intend bidding for flow tees must possess the records of a successful proof
test for tees used in the fabrication of flow tees, in accordance with the provisions of ASME B
16.9/ MSS-SP-75, as applicable. These records shall be submitted at the time of bidding
qualifying the entire range of fittings offered.
4.0 MATERIALS
4.1 Materials for the pressure containing parts of the flow tees shall be as indicated in the Flow
Tees Data Sheet. Other parts shall be as per Manufacturer's standard suitable for the service
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — PJI rights reserved

atMINERS FOR FLOW TEES FOR ONSHORE 6-71-0025 Rev. 4
g7j
liapteg W
INDIA Li miTED PIPELINES
(A GoN India U.0.1*.ngl Page 5 of 8
conditions and shall be subject to approval by Company. In addition, the material shall also
meet the requirements specified hereinafter.
4.2 The Carbon Steel used in the manufacture of flow tees shall be fully killed.
4.3 Each heat of steel used for the manufacture of pressure containing parts of the flow tees shall
have Carbon Equivalent (CE) not greater than 0 45 based on check analysis calculated as per
the following formula:
Mn Cr + Mo +V Ni + Cu
CE = C + +
6 5 15
4.4 For flow tees specified to be used for Gas service or LPG service, Charpy V-notch test shall be
conducted at 0°C for each heat of steel used in the manufacture of pressure containing parts of
flow tee. The test procedure shall conform to MSS-SP-75 / ASTM A370. The average
absorbed impact energy values of three full-sized specimens of base metal, weld metal and
HAZ shall be 27 joules, unless otherwise indicated in the Data Sheet. The minimum impact
energy value of any one specimen shall not be less than 22J. Results of charpy test shall be
recorded.
When Low Temperature Carbon Steel (LTCS) materials are specified in Data Sheet or offered
by Manufacturer, the Charpy V-notch test requirements of applicable material standard shall
be complied with.
4.5 For flow tees specified to be used for Gas service or LPG service, hardness test shall be carried
out as per ASTM A370 for each heat of steel used in the manufacture of tees. A full thickness
cross section shall be taken for this purpose and the maximum hardness of base metal, weld
metal and HAZ of all the pressure containing parts shall not exceed 248 HV Io. Hardness shall
be recorded.
5.1 Flow tees shall be designed and manufactured in accordance with the provisions of Codes,
Standards and Specifications referred in Section 2.0 of this specification. In addition, design
factor and corrosion allowance, as indicated in the Data Sheet, shall also be taken into account
for design of Flow tees.
5.2 Flow tees shall generally conform to the figure shown in the Data Sheet and shall meet the
following requirements:
a) An internal pipe having the same internal diameter as the connecting pipeline
allowing the passage of scraper/instrumented pigs, shall be provided with holes/slots
located in the centre line of the branch. The holes/slots shall be oriented at 45° angle.
The number(s) and size of holes/slots shall be such as to prevent the pig getting stuck
or damaged without affecting the flow through the branch line. The area of the
holes/slots shall be atleast equal to the internal area of branch size. Calculations for
the area shall be furnished.
b. A seamless/submerged arc welded "tee" as per ASME B 16.9/MSS-SP-75, enclosing

the internal pipe and fixed to it by suitably shaped forged steel rings. Machined steel
rings shall not be used. The center to end dimension of the outlet shall meet the
minimum recommended dimension of the referred standard. Circumferential welding
on the branch outlet is not acceptable. Pups shall not be provided either at the run or at
the branch.

ale? re ENGINEERS FOR FLOW TEES FOR ONSHORE 6-71-0025 Rev. 4
raTiaAl
7;
IMeg‘WF INDIA LIMITED PIPELINES
(A GoN al !nab unoena..9) Page 6 of 8
Tees used for fabrication of flow tees shall be seamless type for run sizes DN _^ 350
mm (14") and shall be either welded or seamless type for run sizes DN 400 mm
(16"). Tees shall conform to ASME B 16.9 for run size upto DN 350 (14"). For run
size DN a 400 mm (16"), the tees shall conform to MSS-SP-75/ASME B 16.9.
The flow tees run/branch diameter and wall thickness shall be as indicated in the Data
Sheet, matching with the connecting pipeline.
5.3 Butt weld ends of flow tees shall be bevelled as per MSS-SP-75.
5.4 All flow tees shall be completely stress relieved as per the provisions of MSS-SP-75.
5.5 Stub-in or pipe-to-pipe connection shall not be used in the manufacture of flow tees. Tees used
for manufacturing of flow tees shall be manufactured by forging or extrusion methods only. In
case flow tees are manufactured using welded tees, the longitudinal weld seam shall be
oriented at least 90° to the branch connection.
provisions of ASME Section IX. The procedure qualification shall include impact test and
hardness test and shall meet the requirements of clause 4.4 and 4.5 of this specification
respectively.
5.7 Repair by welding on parent metal of the flow tee is not permitted. Repair of weld seam by
welding shall be carried out only after specific approval by Company's Inspector for each
repair. The repair welding shall be carried out by the welders and welding procedures duly
qualified as per ASME Section IX and records for each repair shall be maintained. Repair
welding procedure qualification shall include all tests, which are applicable for regular
production welding procedure qualification. All heat treatment and radiography shall be
repeated after the weld repair.
5.8 The tolerance on internal diameter and out of roundness at the ends for welded flow tees shall
be as per applicable connected pipe specification as indicated in the Data Sheet.
6.0 INSPECTION & TESTS
works. Such inspections and tests shall be, but not limited to, the following:
6.1.1 All flow tees shall be visually inspected. The internal and external surfaces of the flow tees
shall be free from any strikes, gauges and other detrimental defects.
6.1.2 Dimensional checks shall be carried out as per the approved drawings.
6.1.3 Chemical composition and mechanical properties shall be checked as per MSS-SP-75/relevant
material standards, and this specification for each heat of steel used.
6.1.4 Non destructive examination of individual flow tees shall be performed as given below:
100% inspection by radiography shall be carried out on all butt welds of pressure
containing parts. Acceptance limits shall be as per API-1104. Radiography shall be
performed after the final heat treatment.
All finished wrought weld ends shall be 100% ultrasonically tested for lamination type
defects for a distance of 25 mm from the end. Any lamination larger than 6.35 mm
shall not be acceptable.
ENGINEERS FOR FLOW TEES FOR ONSHORE 6-71-0025 Rev. 4
5@zir nattgliiif INDIA LIMITED PIPELINES
awn riorenaarrn (A Gout of Incha Pagel of 8
Magnetic particle or liquid penetrant examination shall be performed on cold formed

butt welding tees with extruded outlets. The examination shall be carried out as per
the Supplementary Requirement SR 14 of MSS-SP-75.
Welds, which, in Company's Inspector's opinion, cannot be inspected by radiographic
methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance
criteria shall be as per ASME Section VIII Appendix U and Appendix VI respectively.
All forgings shall be wet magnetic particle examined on 100 % of the forged surfaces.
Method and acceptance shall comply with MSS-SP-53.
All welded flow tees shall be subjected to normalization heat treatment after final
fabrication.
6.2 Company's Inspector reserves the right to perform stage wise inspection and witness tests, as
indicated in clause 6.1 of this specification, at Manufacturer's works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide without charge reasonable
access and facilities required for inspection to the Company's Inspector.
Inspection and tests performed/witnessed by Company's Inspector shall in no way relieve the
Manufacturer shall submit the following certificates to Company's inspector:
Test certificates relevant to the chemical analysis and mechanical properties including
hardness of the materials used for construction as per this specification and relevant
standards.
Test reports on radiographic, ultrasonic inspection and wet magnetic particle

examination.
Test certificates for each flow tees stating that it is capable of withstanding without
leakage a test pressure which results in a hoop stress equivalent to 95% of the
specified minimum yield strength for the pipe with which the flow tee is to be attached
without impairing its serviceability.
Test reports on heat treatment carried out as per specification.
e) Welding procedures and welders qualification reports.
8.0 PAINTING, MARKING & SHIPMENT
8.1 After all inspection and tests required have been carried out/witnessed by Company's
Inspector, entire surface of flow tees shall be thoroughly cleaned to remove grease, dust and
rust and shall be applied with sufficient coats of standard mill coating/corrosion resistant paint,
for protection against corrosion during transit and storage. The surface preparation shall be
carried out by shot blasting to SP6 in accordance with "Steel Structures Painting Council -
Visual Standard - SSPC-VIS-I".
8.2 Manufacturer shall indicate the type of mill coating / corrosion resistant paint used in the
drawings submitted for approval.
8.3 Ends of flow tees shall be suitably protected to avoid any damage during transit. Metallic or
high impact plastic bevel protectors shall be provided for weld ends of flow tees.

(arm eaw
ENICklEFRS
(ear imeg INDIA
l.MTED
IA God of India Unartaling)
FOR FLOW TEES FOR ONSHORE
PIPELINES
6-71-0025 Rev. 4
Page 8 of 8
8.4 Flow tees shall be marked with indelible paint with the following data:
Manufacturer's name
Nominal diameter of run and branch
Nominal thickness of run and branch ends
e. Tag number
9.0 DOCUMENTATION

9.1 At the time of bidding, Bidder shall submit the following documents:
Reference list of similar supplies including all relevant details viz. Project, Year of
supply, Client, Location, Size, Rating and Service for the last five years.
Records of successful proof test for tees used for fabrication of flow tees, qualifying
the range of sizes quoted.
and specifications for company's review and information:
General arrangement drawings of flow tees with overall dimensions and cross
sectional drawing including relevant calculations for pressure containing parts.
Calculations for the no. and size of holes/slots and flow area.
c. Heat treatment details.
9.3 All documents shall be in English Language.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell—All rights reserved

a-a fa
i
1W-ere?
ikreg,
ENGINEERS
INDIA LIMITED
INSULATING JOINTS
(ONSHORE)
6-71-0026 Rev. 4
Page 1 of 10
rieur wfrk:r TrRw 1-4ff-br
FOR
INSULATING JOINTS
(ONSHORE)
REVISED & REISSUED AS STANDARD SKJ VM DM

REVISED & REISSUED AS STANDARD MKM VM AS VC
3 21-11-06
SPECIFICATION
REVISED & REISSUED AS STANDARD SK SJ VC AS
/ 16-10-98 SPECIFICATION
0 15-06-89 ISSUED AS STANDARD SPECIFICATION SK RKD SA
Standards Standards
Committee Bureau
Rev. Prepared Checked
No by by
Approved by

ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
Igelliagreg INDIA LIMITED
Abbreviations:

CE Carbon Equivalent
DN Nominal Diameter
LTCS Low Temperature Carbon Steel
RTJ Ring Type Joint
Members : Mr. S. K. Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal

arel ENGINEERS INSULATING JOINTS
Itg7 Etweg, INDIA LIMITED
(ONSHORE)
6-71-0026 Rev. 4
Page 3 of 10
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS 4
4.0 DESIGN AND FABRICATION 5
8.0 DOCUMENTATION 9
9.0 FIG. 4.1 & Fig. 4.2 10
Format No. 8-00-0001-F1 Rev .0 Copyright EIL - All rights reserved

5di*ZI-eq smolt ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
is INDIA LIMITED (ONSHORE)
1g7 (151-'
d, Co,1 m inaa Undenaxing, Page 4 of 10
1.0 SCOPE
supply of carbon steel insulating joints to be installed in onshore pipeline systems handling
non-sour hydrocarbons in liquid or gaseous phase including Liquefied Petroleum Gas (LPG).
Reference has also been made in this specification to the latest edition (edition enforce at the
ASME B 31.4 Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids
ASME B 31.8 Gas Transmission & Distribution Piping Systems.
ASME B16.5 Steel Pipe Flanges and Flanged Fittings.
ASME B 16.25 Butt Welding Ends
e) ASTM A-370 Standard Test Methods and Definitions for Mechanical

0 ASME Section VIII - Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Section IX Boiler and Pressure Vessel Code - Welding and Brazin g
Qualification
API 1104 Specification for Welding Pipeline and Related Facilities
MSS-SP-53 Quality Standard for Steel Castings and Forgings for Valves,
Flanges and Fittings and Other Piping Components -
Magnetic Particle Examination Method
MSS-SP-75 Specification for High Test Wrought Welding Fittings
k) NACE SP 0286 Standard Recommended Practice - Electrical Isolation of

Cathodically Protected Pipelines
I) SSPC-VIS-I Steel Structures Painting Council-Visual Standard
m) API SL Specification for Linepipe
Specifications referred to in this specification, the requirements of this specification shall
govern.
3.0 MATERIALS
3.1 Material for the pressure containing parts of the insulating joints shall be as indicated in the
Insulating Joint Data Sheets. Other parts shall be as per the Manufacturer's standard (suitable
for the service conditions indicated in the Insulating Joint Data Sheets), which shall be subject
to approval by Company. In addition, the material shall also meet the requirements specified
hereinafter.

4SiifraeY ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
511gtIf 0151:eg, INDIA LIMITED (ONSHORE)
Gen d mu i.M1aertairy Page 5 of 10
All process-wetted parts, metallic and non-metallic shall be suitable for the commissioning
fluids and service specified by the Company. Manufacturer shall confirm that all wetted parts
are suitable for treated water/seawater environment, which may be used during field testing.
3.2 Carbon steel used in the manufacture of insulating joints shall be fully killed.
3.3 Insulating Joints which are subject to field weldin g by Company, shall have carbon equivalent
(CE) not exceeding 0.45 based on check analysis for each heat of steel used, as calculated by
the following formula:
Mn Cr + Mo +V Ni +Cif
CE = C + +
6 5 15
3.4 For insulating joints specified to be used for Gas service or LPG service, Charpy V-notch test
shall be conducted on each heat of steel used in the manufacture of all pressure containing
parts including pipe pups & retainer rings of Insulating Joints. The test procedure shall
conform to ASTM A370. Unless specified otherwise, the Charpy V-notch test shall be
conducted at 0° C. The average absorbed energy value of three full sized specimens shall be
27 J. The minimum impact energy value of any one specimen of the three specimens analysed
as above, shall not be less than 22 J. Results of Charpy test shall be recorded.
be complied with.
3.5 For insulating joints specified to be used for Gas service or LPG service, Hardness test shall
be carried out as per ASTM A 370 for each heat of steel used in the manufacture of all
pressure containing parts. A full thickness cross section shall be taken for this purpose and the
maximum hardness of base metal, weld metal and HAZ of all the pressure containing parts
shall not exceed 248 HV i o. Hardness shall be recorded.
3.6 Insulation material shall be minimum 20 mm thick and shall comply with Section 5, NACE
RP 0286.
4.0 DESIGN AND FABRICATION
4.1 Mechanical
4.1.1 Insulating joints shall be of integral type fabricated by welding and with pups on either side as
shown in Fig. 4.1 & Fig. 4.2. Bolted and threaded joints are not permitted. Insulating Joints of
design, not having closing welds, are not acceptable.
4.1.2 Insulating joints shall be designed using the design principles of ASME Section VIII Div. 1.
The design shall be checked for the following two cases:
Case I : Design pressure ( as per Data Sheet) and Axial Force (F).
The Axial force shall be calculated as under:
F=0.1 xSxA
Where
SMYS of connected pipe (refer Data Sheet)
A Metal cross-sectional area of connected pipe.
Format No. 8-00-0001-F1 Rev. 0 Copyright DL — All rights reserved

a rei amq ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
! g
Itga faire MID
INDIA LITE
Noma (ONSHORE) Page 6 of 10
The allowable stress in this case shall be less than or equal to 0.5 x SMYS of insulating joint
material.
Case II : Hydrostatic Test Pressure

The allowable stress in this case shall be less than or equal to 90% of SMYS of insulating joint
material.
All design parameters shall be as per Insulating Joint Data Sheet. Detailed design calculations
shall be submitted for Company approval.
4.1.3 A corrosion allowance as indicated in the Insulating Joint Data Sheet shall be considered in
design.
4.1.4 Insulating joints shall not restrict the pipeline bore and shall allow free passage of scraper and
instrumented pigs.
4.1.5 Insulating joint shall be designed to withstand a sustained internal vacuum of at least one (1)
4.1.6 The joint between pipe pup pieces and main forging shall be full penetration butt weld type.
Weld design shall be such as resulting in a weld joint factor of 1.0.
4.1.7 Butt weld ends shall have ends prepared as per ASME B 16.25. However, end preparation for
butt welding ends having unequal thickness with respect to connectin g pipe, shall be as per
ASME B.31.4/B 31.8 as applicable.
4.1.8 Insulating joints shall be suitable for aboveground or under ground installation as specified in
the Insulating Joint Data Sheet.
4.1.9 The reinforcement of inside weld seam, in case of pups fabricated from LSAW pipes, shall be
removed for a distance of at least 50 nun from each end.
4.1.10 All welds shall be made by welders and welding procedures qualified in accordance with the
provisions of ASME Section IX. The procedure qualification shall include impact test and
hardness test and shall meet the requirements of Para 3.4 and 3.5 respectively of this
specification.
4.1.11 Repair welding on parent metal is not allowed. Repair of welds shall be carried out only after
specific approval by Company's Inspector for each repair. The repair welding shall be carried
out by welders and welding procedures duly qualified as per ASME Section IX and records
for each repair shall be maintained. Repair welding procedure qualification shall also include
impact test and hardness test when required as per Clause 3.4 and 3.5 of this specification and
shall meet the requirements as specified therein. Radiography shall be performed after the
weld repair.
4.1.12 The tolerance on internal diameter and out of roundness at the ends for Insulating joints shall
be as per applicable connected pipe specification as indicated in the Data Sheet.
4.2 Electrical
4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 KV
4.2.2 Two cleats as shown in Fig. 4.1 & Fig. 4.2, shall be provided on the pups on either side of the
insulating joint for connecting 10 mm 2 and 50 mm2 cables for measurement/shorting purposes.
Cleats shall be attached to the insulating joint by welding.
Format No. 8-00-0001-F1 Rev 0 Copyright EIL - All rights reserved

orilfaelel ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
ig7 tilarg INDIA LIMITED
,A G. et inaa undeliak.9, (ONSHORE) Page 7 of 10
4.3 Insulating Material
The design of insulating material shall conform to following requirements:
4.3.1 The electric resistance does not decrease with time.
4.3.2 The insulating material shall not deform.
4.3.3 The insulating material shall be resistance to chemical attack by transferred fluid under design
temperature and pressure.
4.3.4 The transferred fluid does not penetrate into the structure of the insulating material under
design conditions of pressure and temperature.

specification and the relevant codes, prior to shipment at his Works. Such inspection and tests
shall be, but not limited to, the following
5.1.1 All insulating joints shall be visually inspected. The internal and external surfaces shall be free
5.1.2 Dimensional checks shall be carried out as per the Company approved drawings.
5.1.3 Chemical composition and mechanical properties including hardness shall be checked as per
relevant material standards and this specification, for each heat of steel used.
5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below:
All butt welds and repair welds of pressure containing parts shall be examined 100%
by radiography. Acceptance limits shall be as per API 1104.
Welds, which in Company's opinion cannot be inspected by radiographic methods,

shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall
be as per ASME Section VIII Appendix U and Appendix VI respectively.
All forgings shall be wet magnetic particle inspected on 100% of forged surfaces.
Method and acceptance shall comply with MSS-SP-53.
All finished weld ends shall be 100% ultrasonically tested for lamination type defects
for a distance of 50 mm from the ends. Any lamination larger than 6.35 mm shall not
be acceptable.
All fillet welds of thickness <6 run shall be examined 100% by magnetic particle
inspection and ^6 mm shall be examined 100% by UT. Acceptance criteria for MPI
and UT shall be as per ASME Sec VIII Appendix VI and Appendix U respectively.
5.1.5 Insulating joints shall be hydrostatically tested to a pressure as indicated in the Insulating Joint
Data Sheet. The test duration shall be 15 minutes.
5.1.6 After hydrostatic test, insulating joints shall be tested with air at 5 kg/cm' for 10 minutes. The
tightness shall be checked by immersion or with a frothing agent. No leakage will be accepted.

bra ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
sill Zs INDIA LIMITED
nd (ONSHORE) Page 8 of 10
5.1.7 Dielectric Test
Insulation resistance of each insulating joint shall be at least 25 Mega Ohms, when
checked with 500-1000 V DC.
In addition, prior to and after hydrotesting, each insulating joint shall be tested for
dielectric integrity at 5000 V AC, 50 Hz for one minute and the leakage current before
and after the hydrostatic test shall be equal. Testing time, voltage and leakage shall be
recorded and certified.
No repair shall be permitted to the insulating joints failed in the above mentioned tests.
clause 5.1 at Manufacturer's Works prior to shipment. Manufacturer shall g ive reasonable
notice of time and shall provide without charge reasonable access and facilities required for
inspection by the Company's Inspector. Inspection and tests performed/witnessed by the
Company's Inspector shall in no way relieve the Manufacturer's obligation to perform the
required inspection and tests.

6.1 Manufacturer shall submit followin g certificates to Company's inspector:
materials used for construction of insulating joint as per this specification and relevant
standards.
Test reports on non-destructive testing.
Test certificates for hydrostatic and air tests.
Test certificate for electrical tests.
7.1 After all inspection and tests required have been carried out, Insulating joint surface shall be
thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion
resistant paint as per manufacturer's standard suitable for normal corrosive environment
unless otherwise specified in the data sheets. Surface preparation shall be carried out by shot
SSPC-VIS-I". External surfaces of buried insulating joints shall be painted as per
manufacturer's standard or as specified in data sheet. Manufacturer shall indicate the type of
corrosion resistant paint used, in the drawings submitted for approval.
7.2 Insulating joints shall be marked with indelible paint with the following data:
Manufacturer's name
Suitable for inch Nominal diameter pipeline
End thickness in mm
Material
Design Pressure / Hydrostatic Test Pressure
ANSI Class Rating
Tag No.
Year of Manufacture

16ira4elI ENGINEERS INSULATING JOINTS 6-71-0026 Rev. 4
11=g7IM-arg INDIA LIMITED (ONSHORE) Page 9 of 10
7.3 Insulating joints shall be suitably protected to avoid any damage during transit. Metallic or
high-impact plastic bevel protectors shall be provided for weld ends.
7.4 Only those insulating joints, which have been inspected and certified by Company's Inspector,
shall be shipped.
8.0 DOCUMENTATION

8.1 At the time of bidding, Bidder shall submit the following documents:
a. Reference list of similar supplies including all relevant details viz. Project, Year of
supply, Client, Location, Size, Rating and Service for the last seven years
8.2 After the placement of order, the Manufacturer shall submit the following documents for
Company's information & review.
General Arrangement drawing with overall dimensions and cross sectional drawings
alongwith calculation of pressure containing parts.
Company's comments, if any, shall be informed to manufacturer and they shall

comply with Company's comments.
Fabrication drawings and relevant calculations for pressure containing parts.
Welding procedure and method of manufacture for all phases of manufacture.
format also.

rn ENGINEERS
$PRzIr [loft ‘..}
Iiirtei(
41)
INDIA LIMITED
INSULATING JOINTS
( ONSHORE )
6-71-0026 Rev. 4
Page 10 of 10
ul 300
-t
180
180 INSULATING
JOINT
PUP CLEAT PUP
n re {—
FIGURE — 4.1
(For Sizes upto 8" NB)
Si
10:] ; RI INSULATING 100 3 :JO 100
JOINT
PUP CLEAT PUP
n 1 re
FIGURE — 4.2
(For Sizes above 8" NB)

atPZiek
Sig?31 Rkreg,
cij ENGINEERS
INDIA LIMITED
SCRAPER TRAPS
(ONSHORE)
6-71-0031 Rev. 4
FA Gov/ ol ode ncenakm9, Page 1 of 10
tictAiR ttr faR +iiicb foft
FOR
SCRAPER TRAPS
(ONSHORE)

REVISED & REISSUED AS STANDARD MKM VM AS VC
SPECIFICATION
1 01-09-98 REVISED & REISSUED AS STANDARD SM TBG VC AS
SPECIFICATION
0 09-06-89 ISSUED AS STANDARD SPECIFICATION MK GD SA
Standards Standards
No by by
Approved by

ENG NEERS SCRAPER TRAPS 6-71-0031 Rev. 4
INDIA LIMITED
Abbreviations:

OD Outside Diameter
QOEC Quick Opening End Closure
SAW Submerged Arc Welded
SMYS Specified Minimum Yield Strength

Mr. Raj Kumar
Mr. M. S. Gunjiyal

451M-ae? 44,, ENGINEERS SCRAPER TRAPS 6-71-0031 Rev. 4
la9e 5 INDIA LIMITED
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS 5
9.0 DOCUMENTATION 9

511=a-zra ENGINEERS SCRAPER TRAPS 6-71-0031 Rev. 4
lagreg INDIA LIMITED
r Goul inaa tinontak.g) (ONSHORE) Page 4 of 10
1.0 SCOPE
supply of scraper launching and receiving traps to be installed in onshore pipeline systems
transporting non-sour hydrocarbons in liquid or gaseous phase including Liquefied Petroleum
Gas (LPG).

Reference has also been made in this specification to the latest edition (edition enforce at the
a. ASME B 31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids.
ASME B 31.8 - Gas Transmission and Distribution Piping Systems.
ASME B 16.5 - Steel Pipe Flanges and Flanged Fittings.
ASME B 16.9 - Factory made Wrought Steel Butt Welding Fittings.
ASME B 16.11 - Forged Steel Fittings, Socket- Welding and Threaded.
ASME B 16.25 - Butt-welding Ends.
g. ASME B 16.47 - Large Diameter Steel Flanges
I1. API 1104 Specification for Welding Pipeline and Related Facilities.
i. MSS-SP-53 Quality Standard for Steel Castings and Forgings for Valves,
Flanges and Fittings and other Piping Components -
Magnetic Particle Examination Method.
MSS-SP-75 Specification for High Test Wrought Welding Fittings.
k. MSS-SP-97 Integrally Reinforced Forged Branch outlet Fittings- Socket

Welding, Threaded & Butt Welding Ends.
SSPC-VIS-I Steel Structures Painting Council-Visual Standard.
ASME Sec VIII Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Sec IX Boiler and Pressure Vessel Code - Welding and Brazing
Qualification
o. ASTM A 234 Specification for Piping Fittings of Wrought Steel and Alloy
Steel for Moderate and Elevated Temperature.
P. ASTM A-370 Standard Test Methods and Definitions for Mechanical

Specifications referred to in this specification, the requirements of this specification shall
govern.

NtP-ZreqENGINEERS SCRAPER TRAPS 6-71-0031 Rev. 4
sig-LITIaRtag INDIA LIMITED (ONSHORE) Page 5 of 10
3.0 MATERIALS
3.1 Materials of main components used in manufacture of traps shall be as indicated in the Data
Sheet. Other components shall be as per Manufacturer's Standard (suitable for the service
conditions indicated in Data Sheet) and shall be subject to approval by Company. In addition,
the material shall also meet the requirements specified hereinafter.
The SMYS of steel used for manufacture of Quick Opening End Closure (QOEC) shall be as
indicated in data sheet.
3.2 Carbon Steel used in the manufacture of traps and end closures shall be fully killed
3.3 Material of the ends to be field welded by Company shall have carbon equivalent less than or
equal to 0.45, based on check analysis for each heat of steel, calculated according to the
following formula:
Mn Cr + Mo +V Ni + Ctt
CE = C + +
6 5 15
3.4 For Scraper traps, specified to be used for Gas service or LPG service, Charpy V-notch test
shall be conducted on each heat of steel used in the manufacture of pressure containing parts
of Scraper Traps. The test procedure shall conform to ASTM A370. Unless specified
otherwise, the Charpy V-notch test shall be conducted at 0° C. Results of Charpy test shall be
recorded.
The average absorbed impact energy values of three full-sized specimens of base metal, weld
metal and HAZ shall be 27 Joules, unless otherwise indicated in the Data Sheet. The minimum
impact energy value of any one specimen of the three specimens analyzed as above, shall not
be less than 22 Joules.
be complied with.
3.5 For Scraper traps, specified to be used for Gas service or LPG service, Hardness test shall be
carried out as per ASTM A 370 for each heat of steel used in the manufacture of pressure
containing parts of traps. A full thickness cross section shall be taken for this purpose and the
maximum hardness of base metal, weld metal and HAZ of all the pressure containing parts
shall not exceed 248 HV I o. Hardness shall be recorded.
411 DESIGN AND CONSTRUCTION REQUIREMENTS
4.1 Scraper traps shall be designed and manufactured in accordance with the provisions of Codes,
Standards and Specifications referred in clause 2.0 of this specification. In addition, design
parameters indicated in the data sheets, shall be taken into account for design of scraper traps.
4.2 The scraper traps shall be suitable for handling scraper / cleaning / gauging / batching /
instrumented pigs and shall conform to the minimum dimensions given in scraper trap data
sheets. Dimensions not shown specifically in the Data Sheet shall be as per manufacturer's
standard and shall be subject to approval by Company.
4.3 The cylindrical portion of the trap shall be designed as per design code and design factor
indicated in the Data Sheet. Scraper trap shall be provided at the end with Quick Opening End
Closure (QOEC) as indicated in Data Sheet. Quick end closure shall be designed, as per
ASME Sec. VIII, Div. 1 with allowable stress level limits/design factor applicable for traps,
for the design conditions indicated in the Data Sheet. A corrosion allowance, as indicated in

SiI1=aZfei e ENGINEERS SCRAPER TRAPS 6-71-0031 Rev. 4
oga faireg INDIA LIMITED
the Data Sheet shall be considered in design of the traps and closures. Quality of welding shall
be such that weld efficiency factor of 1.0 is achieved.
4.4 The trap body/neck diameter and minimum length shall be as indicated in the Data Sheets.
Circumferential weld on scraper trap body and neck shall not be permitted.
4.5 Concentric or eccentric reducer used in the manufacture of traps shall be seamless type for
sizes upto and including NPS 16 and welded type for sizes NPS 18 and above. Reducers shall
conform to ASME B 16.9/ MSS-SP-75 as indicated in the data sheet. End thicknesses of
reducer shall match with the adjoining body/ neck thickness.
4.6 Connections for vents and drains shall be provided on each trap. Sizes for vents and drains
shall be as indicated in Data Sheet. The traps shall be provided with a suitable slope and the
drain location shall be such that complete drainage of the trap is possible.
4.7 All branch connections shall be made by weldolet/nippolet/sockolet or by extrusion as

indicated in Scraper Trap Data Sheet. All weldolets shall conform to MSS-SP-97 and all
nippolets shall be as per Manufacturer's Standard. The extruded openings shall be adequately
heat-treated and stress relieved.
Stub-in or pipe-to-pipe connection shall not be used for making branch connections.
4.8 End connections of traps shall be flanged or butt-welded as indicated in data sheets.
Flanged end, if specified, shall have flanges as per ASME B16.5 for sizes upto NB
600 mm (24") excluding NB 550 mm (22") and as per MSS-SP-44/ASME B16.47
Series A for sizes NB 550 mm (22") and for NB 650 mm (26 inches) and above.
Flange face shall be either raised face or ring joint type (RTJ) as indicated in Data
Sheet. Flange face finish shall be serrated or smooth as indicated in Data Sheet. In
case of RTJ flanges, the groove hardness shall be minimum 140 BHN.
Butt weld ends, if specified, shall have ends prepared as per ASME B16.25. However,
end preparation for butt-welding ends having unequal thicknesses with respect to
connecting pipe shall be as per ASME B3I.4/ ASME B31.8, as applicable.
4.9 The quick opening end closure shall be of clamp ring/band-lock type or equivalent design and
shall consist of a safety pressure release system allowing the opening only when there is no
pressure in the trap. End closure shall be hand operated by a single lever operation and
operable by one operator. End closures of size NB 600 (24") and above shall be fitted with
worm gear operator for the opening of the closure. Hinge of the closure shall be so designed
that the weight of the end closure is fully supported without sagging. Screwed type or plug-in
type of end closures are not permitted.
4.10 Receiving traps shall be provided with a pig signaller at a location indicated in the Scraper
Trap Data Sheet. Pig signaller shall be suitable for bi-directional operation and shall have
visual flag and manual reset mechanism. The pig signaller shall also have provision for remote
indication, when indicated in Pig Signaller Data Sheet. The pig signaller shall conform to the
requirements of relevant pig signaller specification and data sheet.
4.11 The pig receiving traps shall be equipped with a half internal removable filtering basket
consisting of a punched plate with at least five rows of drain holes. The filtering basket shall
slide on guides/rails or wheels and in all cases the material of the parts being in contact with
each other shall be of anti-spark type. The filtering basket shall be provided with suitable
stops. Lock bracket shall be provided to such that the basket does not slide within the trap.
Rear end of the basket shall be provided with suitable lug to enable retrieval of the basket by
hooks. The handling system (for inserting and retracting the scraper and instrumented pigs

ig_itaZfe?ENCJNEERS SCRAPER TRAPS 6-71-0031 Rev. 4
Igair @Reg INDIA LIMITED
from the trap) shall be complete with handling devices. In case any rails are required for
sliding of the handling system, the same shall be provided by the scraper trap manufacturer.
4.12 Fabricated steel supports, minimum two numbers at suitable spacing shall be provided with
traps for mounting on concrete blocks. These supports will not be subjected to pipeline
anchorage forces and shall be free sliding supports. Support base plate shall not have any
holes. No foundation bolts shall be supplied. The material of support shall be compatible with
trap material for welding purposes. All welds shall be examined by magnetic particle method.
4.13 Completed assembly shall be stress relieved as per the provisions of applicable design codes.
provisions of ASME Sec. IX. The procedure qualification shall also include impact test and
4.15 Repair by welding on parent metal is not allowed. Repair of welds by welding shall be carried
out only after specific approval by Company's Inspector for each repair. The repair welding
_ shall be carried out by the welders and welding procedures duly qualified as per ASME Sec.
IX and records for each repair shall be maintained. The repair welding procedure qualification
shall also include impact test and hardness test when required as per Clause 3.4 and 3.5 of this
specification and shall meet the requirements as specified therein. Radiography and heat
treatment shall be repeated after the weld repair.
4.16 The tolerance on internal diameter and out of roundness at the ends for the welding end of the
neck (at the end where connecting pipeline will be welded) shall be as per applicable
connected pipe specification as indicated in the Data Sheet.
5.1 The manufacturer shall perform all inspection and tests as per the requirements of this
5.1.1 All traps shall be visually inspected. The internal and external surfaces of the scraper traps
shall be free from any strikes, gouges and other detrimental defects.
5.1.2 Dimensional check shall be carried out as per the Company approved drawings.
5.1.4 Hydrostatic test shall be conducted for all scraper traps complete in all respects including
QOEC, including mounting of pig indicators at a pressure equal to 1.25 & 1.5 times the design
pressure for liquid & gas service respectively unless otherwise indicated in the data sheet. The
test pressure shall be maintained and held for a minimum period of one hour.
5.1.5 All butt welds shall be 100% radiographically inspected. Procedure and acceptance criteria
shall be as per API 1104.
5.1.6 Ultrasonic or magnetic particle inspection shall be carried out on all welds, which in Company
Inspector's opinion cannot be radiographically inspected. Procedure and acceptance criteria
shall be as per ASME Sec. VIII, Appendix U and Appendix VI respectively.
5.1.7 All finished wrought weld ends shall be 100% ultrasonically inspected for lamination type
defects for a distance of 50mm from the end. Any laminations larger than ('A") 6.35 mm shall
not be acceptable.

sga glffreg
15iftel ENGINEERS
INDIA LIMITED
SCRAPER TRAPS
(ONSHORE)
6-71-0031 Rev. 4
Page 8 of 10
5.1.8 All forgings shall be wet magnetic particle examined on 100% of the forged surfaces. Method
and acceptance shall comply with MSS-SP-53.
5.1.9 A minimum of two closing and opening cycles shall be performed and correct operation of
both quick opening closure and safety system shall be ascertained.
5.2 Company's Inspector reserves the right to perform stage wise inspection and witness tests,
including hydrostatic test, as indicated in specification at Manufacturer's Works prior to
shipment. Manufacturer shall give reasonable notice of time and shall provide without charge
reasonable access and facilities required for inspection, to the Company's Inspector.
Manufacturer's obligation to perform the required inspections and tests and of specific
integrity of the scraper traps.
Test certificates relevant to the chemical and mechanical properties of the materials
used for manufacture of trap as per relevant standards and this specification.
Hydrostatic test certificates.
Test Reports on radiography, ultrasonic inspection and magnetic particle examination.
Test Reports on heat treatment carried out, if any.
Welding procedures and welders qualification reports.
those traps which have been inspected and certified by the Company's Inspector shall be
dispatched from Manufacturer's works.
thoroughly cleaned to remove grease. dust and rust. Surface preparation shall be carried out by
shot blasting to SP-6 in accordance with "Steel Structures Painting Council Visual Standard-
SSPC-VIS-I". Machined parts shall be coated with anti-rust removable paint and non-
machined parts shall be applied with two coats of protective paint. Manufacturer shall indicate
the type of paint used in the drawings submitted for approval.
7.2 Before shipment, traps shall be properly packed against damage during transportation. All
machined surfaces subject to corrosion during transit shall be well protected by coat of grease
or other suitable material. All traps shall be provided with suitable protectors, for flange faces,
securely attached to the traps. Bevel ends shall be protected with metallic or high impact
7.3 Marking shall be done on a stainless steel plate and affixed to the trap body by means of
corrosion resistant fasteners. Marking shall include the following:
Manufacturer's Name
Trap/Neck diameter, thickness

stirazre? foaq ENGINEERS SCRAPER TRAPS 6-71-0031 Rev. 4
51=47kilteg. WA LIMITED (ONSHORE) Page 9 0110
Material
ASME Class Rating
0 Tag Number
Design pressure
Design Temperature
0 Year of manufacture
j) Empty weight of the trap assembly.
8.0 SPARES
8.1 Manufacturer shall recommend and quote separately the spares for traps required for two (2)
years of normal operation with special attention to consumable items such as gaskets, seals,
etc. for end closure.
8.2 Manufacturer shall recommend and quote unit price separately for the accessories and special
tools required for operation & maintenance of the traps.
8.3 Manufacturer shall recommend and supply the spares for Scraper Traps required for start-up &
commissioning. As a minimum, the same shall include 200% extra consumable spares viz.
gasket/ 0-rings etc. and price of all such spares shall be included in the quoted price.
9.0 DOCUMENTATION

General arrangement drawing of scraper trap, quick opening end closure and pig
signallers with overall dimensions and list of spares as per clause no. 8.0.
Reference list of similar supplies for the past five years including project, client, year
of supply, client, location, size, rating, service and contact person.
and specifications for company's information & review:
Trap assembly and sectional drawings showing all parts and accessories with materials
and dimensions.
Support Assembly drawing. Hydrotest load on both the supports of the Scraper Trap.
c) Arrangement & details of foundation bolts for pig handling and lifting system, where
applicable.
9.3 Prior to shipment, the Manufacturer shall submit the following:
a) Test certificates as listed in clause 6.0 of this specification.

owzrei STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
U wP1
EN G INEERS
SCRAPER TRAPS 6-71-0031 Rev. 4
$'WLIT degINDIA LIMITED (ONSHORE) Page 10 of 10
b) Manual for installation, erection instructions, maintenance and operations instructions

including a list of recommended spares for the scraper traps.
93 Final drawings/ documents as indicated in clause no. 9.2 above shall be submitted in soft
format also.

IStfaaek,,,,,, ENGINEERS FOR PIG SIGNALLERS 6 .71-0033 Rev. 4
a 0154-eg 41. INDIA LIMITED (ONSHORE)
r A
ha Unn") Page 1 of 7
ftvi rttimo4 Rtit Hit* tea
FOR
PIG SIGNALLERS
(ONSHORE)
3
13-03-12
22-11-06
SPECIFICATION
nste-
MKM
SKJ
VM
VM
AS
DM
VC
SPECIFICATION
2 24-10-01 MKM KKS SJ GRR
SPECIFICATION
'I 21-09-98 ALP AS VC AS
SPECIFICATION
Standards Standards
Rev. Prepared Checked Committee Bureau
No by by
Approved by

ISrazieiENGINEERS FOR PIG SIGNALLERS 6-71-0033 Rev. 4
SZII 21571-eg INDIA LIMITED (ONSHORE)
IA GA of Willa undertamngp Page 2 of 7
Abbreviations:

MSS-SP Manufacturers Standardization Society -• Standard Practice
OD Outside Diameter

Mr. Raj Kumar
Mr. M. S. Gunjiyal

OWE? ft,
;i ENGINEERS FOR PIG SIGNALLERS
s'Igzx EifflegW INDIA LIMITED 6-71-0033 Rev. 4
A OAAI 0/ Ind. tidettaionok (ONSHORE) Page 3 of 7
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS 4
9.0 DOCUMENTATION 6

lard-aEl
,
R5reg S ENGINEERS
INDIA LIMITED
IA God Of 1110e unaeptatng)
FOR PIG SIGNALLERS
(ONSHORE)
6-71-0033 Rev. 4
Page 4 of 7
1.0 SCOPE
This specification covers the minimum requirements for the design, manufacture, testing and
supply of Pig Signallers, used for the detection of passage of scraper and instrumented
gauging pigs, to be installed in onshore pipelines transporting non-sour hydrocarbons in liquid
or gaseous phase including Liquefied Petroleum Gas (LPG).

and Other Liquids
ASME B 31.8 Gas Transmission and Distribution Piping Systems
c) MSS-SP-75 Specification for High Test Wrought Butt Welding Fittings
e) ASTM A 370 Standard Test Methods and Definitions for Mechanical

ASME Sec VIII - Boilers & Pressure Vessel Code - Rules for the Construction
of Pressure Vessels
g) ASME Sec IX Qualification Standard for Welding and Brazing Procedures,

In case of conflict between the requirements of this specification and the requirements of
above referred codes, standards and specifications, the requirements of this specification shall
govern.
3.0 MATERIAL
3.1 Material for major components of the pig signallers shall be as indicated in Pig Signaller Data
Sheet. Other components shall be as per Manufacturer's Standard suitable for the service
conditions indicated in Data Sheet, which will be subject to approval by Company. In
addition, the material shall also meet the requirements specified hereinafter.
3.2 Carbon Steel used in the manufacture of Pig Signallers shall be fully killed.
3.3 Scarfed welding base shall have Carbon Equivalent (CE) not greater than 0.45 on check
analysis, calculated as per the following formula:
Mn Cr+Mo+V Ni+Cu
CE=C+ +
6 5 15
4.0 DESIGN AND CONSTRUCTION REQUIREMENT
4.1 Pig signallers shall be designed and manufactured in accordance with the provisions of Codes,
Standards and Specifications referred in clause 2.0 of this specification. In addition, design
parameters indicated in the data sheets, shall be taken into account for design of pig signallers.
4.2 Pig signallers shall be bi-directional type, having tumbler mechanism and laminated trigger
blades. Plunger type pig-signallers are not acceptable. The trigger shall not obstruct or damage
Format No. 8-00-0001-F1 Rev. 0 Copyright El L - All rights reserved

arerre? ENGINEERS FOR PIG SIGNALLERS
INDIA LIMITED 6-71-0033 Rev. 4
$1=4-latiRreg, &M of woo uncertammv (ONSHORE) Page 5 of 7
a passing pig and the trigger shall not be damaged by a passing pig. The penetration of the
trigger into the main pipe shall be kept to a minimum to avoid unnecessary obstruction of the
fluid flow. The trigger shall be of SS316 steal.
4.3 Design of pig signallers shall be such that any possibility of signaller being operated by line
pressure is eliminated. Design of pig signallers shall also be such that repair and installation of
internal/accessories are possible under pressure, without removing the unit from the line.
4.4 Pig signallers shall be provided with a visual indicator to indicate the passage of pigs, by
means of spring loaded metal shaft. The arm shall lock in down position when manually reset.
4.5 When specified in Data Sheet, pig signallers shall be fitted with sealed, weather proof and
explosion proof microswitch for remote signal indication. The area classification and rating of
microswitch shall be as indicated in Data Sheet.
provisions of ASME Section IX.
4.7 When specified in the Data Sheet, pig signallers shall be provided with extension, suitable for
installation on underground pipeline.
5.1.1 All pig signallers shall be visually inspected. The internal and external surfaces shall be free
5.1.2 Hydrostatic test shall be conducted at a pressure equal to 1.25/ 1.5 times the design pressure
for liquid / gas service as indicated in data sheet. Hydrotest duration shall be 15 minutes.
5.1.3 All welds shall be non destructively examined either by ultrasonic or magnetic particle
methods.
5.1.4 The welding end shall be inspected ultrasonically over the entire circumference for lamination
type defects. Any lamination larger than 6.35 mm shall not be acceptable.
5.1.5 Manufacturers shall perform functional tests to establish satisfactory performance of both
manual and electrical indications.
5.2 Company's Inspector reserves the right to perform stage wise inspection and witness tests,
including hydrostatic test, as indicated in specification, at Manufacturer's Works prior to
shipment. Manufacturer shall give reasonable notice of time and shall provide without charge
reasonable access and facilities required for inspection, to the Company's Inspector.

aR€J ENGINEERS FOR PIG SIGNALLERS 6-71-0033 Rev. 4
Sga Mleg INDIA LIMITED
Manufacturer shall submit the following test certificates:
6.1 Test certificates for material compliance as per relevant material standards.
6.2 Test certificates of hydrostatic and functional tests.
6.3 Test reports of ultrasonic/magnetic particle inspection.
7.1 After all inspection and tests required have been carried out, the exterior surface of the pig
signaller shall be thoroughly cleaned, freed from rust and grease and applied with sufficient
coats of corrosion resistant paint. In case of pig signallers with extension, the buried portion
shall be coated with three coats of coal tar epoxy resin. The minimum dry film thickness shall
be 300 microns. Manufacturer shall indicate the type and corrosion resistant paint used in the
drawings submitted for approval.
7.2 A corrosion resistant metal tag shall be permanently attached with each unit, with the
following marking:
Manufacturer's name.
Suitable for installation in mm dia. pipeline
ANSI Rating
Tag No.
7.3 Each unit shall be suitably protected to avoid any damage during transit. Care shall be
exercised during packing to prevent any damage to the welding ends. All machined surfaces
subject to corrosion shall be well protected by a coat of grease or other suitable materials.
8.1 Manufacturer shall furnish list of recommended spares and accessories for pig signallers
required during start-up and commissioning and supply of such spares shall be included in the
price quoted by Manufacturer.
8.2 Manufacturer shall furnish list of recommended spares and accessories (including jacketing
bracket) required for two years of normal operation and maintenance of pig signallers and
price for such spares shall be quoted separately.
9.0 DOCUMENTATION
Documentation (Hard copies / soft copies etc.) to be submitted by Manufacturer to Company

is summarized below.

SallaZIEq S ENGINEERS FOR PIG SIGNALLERS
51T Ran INDIA LIMITED IA C.00 0/ 0103 Undellak/09/ (ONSHORE)
6-71-0033 Rev. 4
Page 7 of 7
General arrangement drawings with overall dimensions and cross-sectional drawings.
Reference list of similar supplies of pig signaller shall be furnished including Project,
Year of supply, Client, Size, Rating and Service for the last five years.
and specifications for company's information & review.
Sectional arrangement drawings showing all parts with reference numbers and
material specification including mounting details of pig signallers on the pipeline/
traps.
Assembly drawing with overall dimensions
c) Cable connection details and cable specification.
9.3 Prior to shipment, Manufacturer shall submit following:
Test Certificates as per clause 6.0 of this specification.
Manual for installation, erection instructions, maintenance and operation instructions.
format also.

OOZE? ENGINEERS FOR CASING INSULATORS AND 6-71-0035 Rev. 4
Ekleg
5111/ INDIA LIMITED
END SEALS Page 1 of 10
au-gtuftzr 194-al At ated7 Thle

Crl
rff‘
- 4-111 ch indribT
FOR
CASING INSULATORS AND END SEALS
4 13.03.12 REVISED & REISSUED AS STANDARD

SPECIFICATION
REVISED & REISSUED AS STANDARD VC
3 22.11.06 SPECIFICATION MKM VM AS
2 24.10.01 REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
SPECIFICATION
1 REVISED & REISSUED AS STANDARD PKM ASr VC AS
12.10.98 SPECIFICATION
0 08.01.90 ISSUED AS STANDARD SPECIFICATION SK RKD SA
Standards Standards
Date Purpose by by Convenor Chairman
No
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright DL — All rights reserved

4.Rangas ENGINEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
g -lagethw INDIA wimp
5 7 CASING INSULATORS AND END 6-71-0035 Rev. 4
(A Gait al India unaciak .91 SEALS Page 2 of 10
Abbreviations:

DN Diameter Nominal

Mr. Raj Kumar
Mr. M. S. Gunjiyal

alzitq a ENGINEERS
CASING INSULATORS AND END 6-71-0035 Rev. 4
$.1g:a tataierwir INDIA
IA Govt
LIMITED
SEALS
of India Undenapng)
Page 3 of 10
CONTENTS
PART-A CASING INSULATORS
1.0 SCOPE 4
2.0 FUNCTION 4
3.0 DESIGN 4
4.0 MATERIAL 5
5.0 INSPECTION AND TESTING 5
PART-B CASING END SEALS
1.0 SCOPE 6
2.0 FUNCTION 6
3.0 DESIGN 6
4.0 MATERIAL 6
PART-C SUPPLEMENTARY REQUIREMENTS

ISilf=eadft ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
da-nr EifYlegWINDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4

coal at India undedaking) SEALS Page 4 of 10
PART - A CASING INSULATORS
1.0 SCOPE
This specification covers the minimum requirements of design, material, manufacture and
supply of casing insulators intended to be used for cased pipeline crossings.
2.0 FUNCTION
Pipeline insulators shall be used to support the carrier pipe inside the casing pipe and
electrically isolate the carrier pipe from the casing pipe at the cased crossings.
The casing insulators shall have the following properties:
Resist cold flow and will not soften at design temperature
Resist corrosion.
Have low friction, to offer less resistance to carrier pipe movement.
Resist mechanical damage while being pulled into the casing.
Have high electrical insulating value and low water absorption, thus preventing
leakage and maintain electrical isolation between carrier and casing pipes.
Have high compressive and impact strength in order to ensure a permanent support to
the carrier pipe.
3.0 DESIGN
The arrangement of insulator shall be generally in accordance with Fig. 3.0. It shall be made
in segments duly held together with cadmium/XYLAN plated bolts and nuts, to be supplied
with casing insulators. The number of segments shall be two for pipe diameters upto DN 300
mm (12"). For larger diameter, the number of segments may be more than two, but their
number shall be kept minimum.
As an alternate design in accordance with fig. 3.1 the casing insulator element shall be a
flexible section containing a toothed male butt strap at one end and an appropriately toothed
female slot on the other end. The same shall be wrapped over the outer surface of the carrier
pipe and locked positively. The insulator rings should be fastened onto the carrier pipe with
the appropriate tool to be provided by the casing insulator manufacturer. No metallic parts or
attachments should be considered in the casing insulator element assembly. The design of
casing insulator should allow for onsite adjustments for any variances within the allowable
O.D. range of pipeline and should grip the pipe firmly without any chances of horizontal
movement or breakage of the insulator rings during installation.
The skid height shall be such that it is slightly less than the value obtained by following
formula:
Casing Internal Dia — Carrier Outer Dia

2
Manufacturer shall obtain prior approval from OWNER on casing insulators drawings/design.

ds, ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
stair fameg FINDIA LIMITED
q- CASING INSULATORS AND END 6-71-0035 Rev. 4
iNPn ewe/Re cr, Ov05/1/ IA Goy/ o/ ioo unoenakingi SEALS Page 5 of 10
4.0 MATERIAL
Casing insulators shall be made of injection moulded high density polyethylene or other
material, equivalent or superior, as approved by OWNER.
The material shall meet the following specifications:
Property Value ASTM Test Method

Dielectric strength 450-500 Volts/Mil D-149
Compressive strength 3200 psi D-695
Tensile strength 3100-5000 psi D-638, D-651
Impact strength 4.0 ft.lb./inch of notch D-256
Water Absorption 0.01% D-570
Manufacturer shall furnish material test certificates of the components used in the assembly of
casing insulators as per the requirements of clause 4.0 of this specification.

aglilei ENGINEERS CASING INSULATORS AND END
sibtar EllMeg, INDIA LIMITED 6-71-0035 Rev. 4
IA Cori of India underlaiong) SEALS Page 6 of 10
PART - B CASING END SEALS
1.0 SCOPE
This specification covers the minimum requirements of design, material, fabrication and
supply of casing end seals intended to be used for pipeline cased crossings.
2.0 FUNCTION
Casing end seals are intended to be used for sealing the annular space between casing pipe and
carrier pipe at casing ends so as to prevent ingress of moisture and water.
3.0 DESIGN
The seals shall be suitable for the casing and carrier pipe diameters as applicable for each case.
The casing end seal shall be flexible to cater for the expansion and contraction of carrier and
casing pipes and shall be able to tolerate both angular and concentric misalignment of casing
pipe without loss of sealing efficiency.
The design of the casing end seals shall permit easy installation of the seal to the cased
pipeline crossing.
It shall provide moisture-proof seals when installed for the entire anticipated life of the buried
pipeline.
Manufacturer shall obtain prior approval from OWNER on casing end seals design/drawings.
4.0 MATERIAL
The casing end-seals shall be made of heat shrink high density radiation cross linked
polyethylene with an adhesive having a melt point suitable for the pipeline service
temperature and ambient temperatures foreseen during construction. End seals material shall
be resistant to heat, cold, vibration, impact, abrasion, corrosive fluids, disbonding, organic and
bio-deterioration. Manufacturer shall confirm compatibility of end seals with carrier pipe
coating.
Casing end seals shall meet following minimum property requirements:
a) Backing (Sleeve and closure patch)
Property Minimum Value Test Method
Tensile strength 2200 psi ASTM D 638
Ultimate Elongation 400 % ASTM D 638
Heat Shock No Visual Cracks, ASTM D 2671

Flow or Drips at 250°C, 4 hours

ENGINEERS
enINDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4
/gM an MAW AA SAWA) IA WA 01 intha Underlakm9I SEALS Page 7 of 10
Adhesive
Ring and Ball 90°C ASTM E 28

Softening Point
Lap Shear 60°C - 25 psi ASTM D 1002

23°C - 250 psi
(2 inch/min.)
System (As Applied)
Peel strength 5 pli ASTM D 1000

(To casing and carrier (10 inch/min.)
pipe and closure patch)
Manufacturer shall furnish material test certificates of the components used in the assembly of
casing end seals as per the requirements of this specification.

Ord-Cele ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
$1g7 &gift'," INDIA LIMITED
Goofof India Un4en".9)
CASING INSULATORS AND END
SEALS
6-71-0035 Rev. 4
Page 8 of 10
PART - C SUPPLEMENTARY REQUIREMENTS
1.0 The manufacturer shall replace, at no extra cost, any material not conforming to the material
and performance requirements of this specification.
2.0 Manufacturer shall submit detailed specification of the materials used in the assemblies, along
with instructions for handling, use and installation of the material for OWNER approval prior
to procurement.
3.0 Manufacturer shall submit all the documents, test reports, records and other information to
OWNER for record after approval as per clause 2.0 above. Number of Copies (Hard copies /
soft copies etc.) shall be as indicated in CONTRACT document.

ard#SENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
Ogar Etraegw INDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4
n)
anznewnwmag WG0,AmmuundertakM SEALS Page 9 of 10
FIG.3.0

am(c
afaeief ENGINEERS
$11g-eir INDIA LIMITED CASING INSULATORS AND END 6-71-0035 Rev. 4

IA Gnu of India Undertaking) SEALS Page 10 of 10
BOTT011 YO
FIG 3.1

Vi12-ada ENGINEERS FOR FIELD JOINT COATING
5g-ar 0151eg's INDIA LIMITED 6-71-0044 Rev. 3
(A Geri nos undenakmg) (ONSHORE PIPELINE) Page 1 of 12
Ow Alg. Atrff
*- fug -m-4-w 1-4-4RT
miimoivo
FOR
FIELD JOINT COATING
(ONSHORE PIPELINES)
govv,-"4
3 18.05.12 REVISED & REISSUED AS STANDARD RK SKJ VM DM
SPECIFICATION
2 06.11.06 REVISED & REISSUED AS STANDARD MKM VM AS VC
SPECIFICATION
1 12.10.98 REVISED & REISSUED AS STANDARD SM TBG VC AS
SPECIFICATION
0 01.08.89 ISSUED AS STANDARD SPECIFICATION MK GD RKD SA
Standards Standards
No Date Purpose by by Convenor Chairman
Approved by

FOR FIELD JOINT COATING 6-71-0044 Rev. 3
(ONSHORE PIPELINE) Page 2 of 12
Abbreviations:

DIN Deutsches Institut ftir Normung
ISO International Organization for Standardization

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Mr. A.K. Chaudhary (PDD)
Mr. G.K. Iyer (HO Construction)
Mr. M.P. Jain (Projects)

Oliatieta ENGINEERS
Stg-ar Eti teg w
NDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
,A Gov' of Ma UntleflaMing) (ONSHORE PIPELINE) Page 3 of 12
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS AND EQUIPMENT 5
4.0 APPLICATION PROCEDURE 7
6.0 REPAIRS 11

Atoovo tolalvA) IA Gat of GU undettatoo9) (ONSHORE PIPELINE) Page 4 of 12
1.0 SCOPE
1.1 This specification establishes the minimum requirements of materials, equipment and
installation of field joint anti-corrosion coating of buried onshore pipelines (for design
temperature upto 65°C) factory coated with either three layer polyethylene or fusion bonded
epoxy coating, by heat shrink wraparound sleeves or by cold applied tapes conforming to DIN
EN 12068 — "Cathodic Protection — External Organic Coatings for the Corrosion Protection of
Buried or Immersed Steel Pipelines used in Conjunction with Cathodic Protection — Tapes and
Shrinkable Materials" and the requirements of this specification. Unless modified/replaced by
this specification, all requirements of DIN EN 12068 shall remain fully applicable and
complied with.
This specification shall be read in conjunction with the conditions of all specifications and
documents included in the Contract between Company and Contractor. Unless specified
otherwise, all sections of this specification shall apply to all specifications referred in this
specification.
Reference has also been made to the latest edition (edition enforce at the time of issue of
enquiry) of the following standards, codes and specifications:
ASTM D-149 : Standard Test Methods of Dielectric Breakdown voltage and

Dielectric strength of solid electrical insulating materials at
commercial frequencies.
ASTM D-257 : Standard Test Methods for D-C Resistance or conductance of

insulating materials
ASTM D-570 : Standard Method of Test for Water Absorption of Plastics.
ISO 8502 — 3 Preparation of Steel Substrates before Application of Paints and

Related Products —Part 3 - Assessment of Dust on Steel
Surfaces Prepared for Painting (Pressure Sensitive Tape
Method).
e) ISO 8503 — 1 Part 1: Specification and definitions for ISO surface profile
comparator for the assessment of abrasive blast cleaned
surfaces.
0 ISO 8503 — 4 Part 4: Methods for calibration of ISO surface profile

comparator and for the determination of surface profile — Stylus
instrument procedure.
SIS-055900 Pictorial Surface Preparation Standard for Painting Steel

Surfaces.
SSPC-SP I Steel Structure Painting Council.
i) DIN EN 12068 : Cathodic Protection — External Organic Coatings for the

Corrosion Protection of Buried or Immersed Steel Pipelines
used in Conjunction with Cathodic Protection — Tapes and
Shrinkable Materials.
In case of conflict between the requirements of this specification and that of above referred
documents, the requirements of this specification shall govern.

The CONTRACTOR shall be familiar with the requirements of these documents and shall
make them readily available at the site to all personnel concerned with carrying out the works
specified in this specification.
3.0 MATERIALS AND EQUIPMENT
3.1 Field joint anti-corrosion coating material shall be either heat shrinkable wraparound sleeve or
cold applied tape suitable for a maximum operating temperature of (+) 60°C (T ma,c) and shall
conform to designation EN 12068 - C HT 60 UV. In addition, the field joint anti-corrosion
coating shall comply the requirements specified in para 3.2 of this specification.
3.1.1 Heat shrinkable wraparound sleeves:
Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized,
ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear
strength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of
a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing
shall be provided with suitable means (thereto-chrome paint, dimple, or other means) to
indicate the desired heat during shrinking in field is attained. The sleeve shall be supplied in
pre-cut sizes to suit the pipe diameter and the requirements of overlap.
The total thickness of heat shrinkable wraparound sleeve in the as applied condition shall be as
follows:
Thickness (mm)
Pipe Size On Pipe body On Weld Bead
(Specified Outside Diameter) (Min.) (Min.)
Up to 18" (457 mm) 2.2 1.8
20"( 508 mm) to 30" (762 mm) 2.5 2.0
32"(813 mm) & above 3.0 2.5
The heat shrink wraparound sleeve shall have the required adhesive properties when applied on
various commercial pipe-coating materials. The pre-heat and application temperatures required
for the application of the shrink sleeve shall not cause loss of functional properties of the pipe
coating.
The Contractor shall propose the manufacturer's details, heat shrinkable sleeve details/
properties and the specific grade of field joint coating system meeting the requirements of this
specification. Contractor shall propose only those coating systems that have been previously
used for pipelines of same or higher size than the size indicated in tender, for a length of 50 km
and above in a single project for similar operating conditions.
3.1.2 Cold Applied Tapes:
Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap. The inner
and outer wraps shall be asymmetric 3-ply tape with co-extruded polyethylene carrier film and
butyl rubber adhesive layers on both sides. The inner layer of butyl rubber adhesive of inner
wrap shall have a thickness of min. 1.0 mm. The inner and outer wraps are to be spirally
wrapped with 55% overlap, equivalent to two layers each providing a total minimum thickness
of 3.0 mm on the pipe body and 2.5 mm on the weld.

satirada ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
gga emeg Imy INDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
(-I AMR anam, (A GM al India Linden:Sinai (ONSHORE PIPELINE) Page 6 of 12
The Contractor shall propose only those cold applied tape coating systems that have been
previously used in pipelines of size 16" and above and a length of 50 km and above in a single
project for similar operating conditions.
3.2 Functionl Requirements of Field Joint Coating
3.2.1 Properties of the PE backing shall be as follows:
SI. No. Properties Unit Requirement Test Method

Tensile Strength
N/mm2 ^ 12 DIN EN 12068
@ + 25°C
Ultimate Elongation @ +25°C. % ^ 250 DIN EN 12068
Dielectric withstand with 1000 KV ^ 30 ASTM D 149
Volts/sec
Water absorption, ASTM D 570
% ^. 0.05
@ + 25°C for 24 hours
Volume Resistivity
e. Ohm-cm .^, 10 15 ASTM D 257
@ + 25°C
3.2.2 Functional Properties of Joint Coating System (As applied)
As applied field joint coating system shall comply the requirements of DIN EN 12068, Table 1
and 2 corresponding to designation DIN EN 12068 - C HT 60 UV, except as modified below:
Cathodic Disbondment Resistance at T. i.e 60°C shall be 20 mm when tested as per

Annexure K of DIN EN 12068. Test shall be carried out at (+) 60°C.
Peel Strength shall be as follows:
Requirement for Test Method

Peel Strength Unit Mech. Resistance as per
Class C (minimum) DIN EN 12068
Inner to Inner (+) @ 23°C N/mm 1.5

Outer to Inner @T„,„,,, N/mm 0.3
Annexure B
@ 23°C N/mm 1.5
Outer to Outer
@T.„ N/mm 0.3
@ 23°C N/mm 3.5
To Pipe Surface
@Tmax N/mm 1.0
Annexure C
@ 23°C N/mm 3.5
To Factory Coating
@Tn,„„ N/mm 1.0
Notes
T max shall be (+) 60 °C.
Contractor shall obtain prior approval from Company regarding the Manufacturer of the joint
coating material and the specific grade of the joint coating system. Complete technical details
along with test certificates complying with the requirements of clause 3.2.1 and 3 2 2 shall be
submitted to Company for this purpose. The Contractor shall furnish test certificates from an
Copyright EIL — All rights reserved

ajtattflai ENGINEERS
/gar tagtewer WA LIMITED (A Sort al India unciettiong)
FOR FIELD JOINT COATING
(ONSHORE PIPELINE)
6-71-0044 Rev. 3
imit71eleaw7 minim)
Page 7 of 12
independent DIN recognized/approved laboratory for all the properties required for the
specified EN designation of field joint coating and the requirements of this specification.
3.3 The materials shall not be older than their period of validity at the time of application by
Contractor. Deteriorated/decomposed material shall be disposed off and replaced by Contractor
at his own expense.
Contractor shall ensure that the coating materials supplied by him are properly packed and
clearly marked with the following:
Manufacturer's name
Material qualification
Batch number
Date of manufacturing and date of expiry
3.4 Contractor shall ensure that the Manufacturer has carried out all quality control tests on each
batch and manufacturer shall provide test certificates to certify that the supplied materials meet
the manufacturer's specifications as indicated in the purchase order and as approved by
COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall
be submitted by Contractor to Company prior to application. Company reserves the right to
have the materials tested by an independent laboratory.
3.5 Materials shall be stored in sheltered storage in the manufacturer's original packing and away
from direct sunlight and in accordance with manufacturer's instructions.
3.6 Contractor shall provide and maintain mobile facilities which contain all necessary equipment
and its spares for cleaning, coating, repairs, inspection and tests.
3.7 Contractor shall furnish sufficient number of the following equipment and the required spares
as a minimum for inspection and test purposes for each crew:
Fully automatic full circle adjustable holiday detector with a visible and audible signal
system for inspection of coatings.
Thickness gauge for measuring thickness.
Contact type temperature recording thermometer (Digital Pyrometer with flat probe
type contact).
Roughness profile measuring (Stylus) instrument
4.0 APPLICATION PROCEDURE
4.1 General
4.1.1 The application procedure shall be in accordance with manufacturer's instructions and the
minimum requirements specified below whichever are the most stringent and shall be
demonstrated to and approved by the Company. Manufacturer's expert shall supervise the
application and shall be available at site upon request during qualification of application
procedure and during construction at Contractor's cost.
4.1.2 Operators for coating application shall be given necessary instructions and training before start
of work, by the Contractor. To verify and qualify the application procedures, all coating applied
during the qualification test, shall be removed for destructive testing as detailed subsequently in
this specification. Contractor shall only utilize those operators who have been approved/pre-
qualified by the field joint coating manufacturer.

Itiakteela ENGINEERS
IlgtEllWrg,
a W- ' INDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
IA Gout of India Undertaking) (ONSHORE PIPELINE) Page 8 of 12
4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with
suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose.
Solvent cleaning procedure according to SSPC-SP1 shall be followed.
4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandable
blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be
used and Garnet material with the second one (in case the authority having jurisdiction have no
objection, the contractor may adopt sand blasting instead of garnet material). During blast
cleaning the pipe surface temperature shall be simultaneously more than 5 °C and more than
3°C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than
85 %. Prior to surface cleaning the surfaces shall be completely dry. The surface shall be
cleaned to a grade Sa 21/2 in accordance with Swedish Standard SIS-055900 with a roughness
profile of 50 — 70 microns. Surface roughness profile shall be measured using an approved
profile comparator in accordance with ISO 8503-1 and shall be calibrated prior to the start of
the work in accordance with ISO 8503-3 or ISO 8503-4. The blast cleanliness shall be checked
on every joint and the roughness profile shall be checked 1 every 10 joints.
Dust, girt or foreign matter shall be removed from the cleaned surface by an industrial vacuum
cleaner. The dust contamination allowed shall be of a rating max 2 as per ISO 8502 -3. The
frequency of checking for dust contamination shall be 1 every 10 joints.
Blast cleaned field joint shall be coated within 2 — 4 hours according to the conditions below:
• Relative Humidity (RH) > 80 % 2 hours

• Relative Humidity (RH) 70 - 80 % 3 hours
• Relative Humidity (RH) < 70 % 4 hours
Pipes delayed beyond this point or pipes showing any visible rust stain, shall be blast cleaned
again.
4.1.5 The field joint surface shall be inspected immediately after blast cleaning and any feature of the
steel surface such as weld spatter, scabs, laminations or other imperfections considered
injurious to the coating integrity, made visible during blast cleaning, shall be reported to the
Company Representative and on permission from Company Representative, such defects shall
be removed by filing or grinding. Pipes affected in this manner shall be then re-blasted cleaned
if the defective area is larger than 50 mm in diameter.
4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded
portions of the coating shall be removed and then suitably trimmed. Portions where parent
coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of
the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface of
uncontaminated factory applied coating.
4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the coating in
order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter.
All these substances shall be removed before coating, to the procedures herein described.
4.1.8 Protection coating shall be applied on the joints immediately after the completion of cleaning
operation.
4.2 Application Procedure for Heat Shrink Wraparound/Sleeves
In addition to the requirements stated above, following shall be complied with:
4.2.1 The wrap around sleeve shall be of a size such that a minimum overlap of 50 mm is ensured
(after shrinking) on both sides of the yard applied corrosion coating of pipes.

IsarazietftENGINEERs FOR FIELD JOINT COATING
sg-ar opiegve INDIAUMITIED 6-71-0044 Rev. 3
imien eremeanaaa.o IA pan of India Undeltakingl (ONSHORE PIPELINE) Page 9 of 12
In the cases where carrier pipe is installed by direct boring/jacking, the overlap on the mill
coating for the leading edges of the joints shall be minimum 200 mm. When this extra overlap
is achieved by providing an additional patch of heat shrink tape/wraparound, it shall be applied
in such a manner that the square edge of the patch on the joint coating is in the direction
opposite to the direction of boring / jacking.
4 2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated either with a
torch moved back and forth over the surface or by induction heating. The minimum pre-heat
temperature shall be as recommended by manufacturer and shall be checked by means of
contact type temperature-recording thermometer (Digital Pyrometer with flat probe type
contact). Temperature indicating crayons shall not be used. Pre-heat temperature shall be
checked on every joint. Care shall be taken to ensure that the entire circumference of the pipe is
heated evenly. Temperature measuring instruments shall be calibrated immediately before the
start of the works and thereafter at intervals recommended by the manufacturer of the
instrument.
4.2.3 Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet film
thickness 200 microns or as per manufacturer's recommendation whichever is higher, to cover
the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating
if recommended by the manufacturer. The wet film thickness of the primer shall be checked on
every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall
be calibrated once per shift.
4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be entirely wrapped
around the pipe within the stipulated time recommended by the manufacturer. Sleeve shall be
positioned such that the closure patch is located to one side of the pipe in 10 or 2 O'clock
position, with the edge of the undergoing layer facing upward and an overlap of min. 50 mm.
Gently heat by appropriate torch the backing and the adhesive of the closure and press it firmly
into place.
4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start
shrinkage of the sleeve beginning from the center of the sleeve and heat circumferentially
around the pipe. Continue heating from the center towards one end of the sleeve until recovery
is completed. In a similar manner, heat and shrink the remaining side. Shrinking has been
completed when the adhesive begins to ooze at the sleeve edges all around the circumference.
The complete shrinking of the entire sleeves shall be obtained without undue heating of
existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The
installed sleeve shall not be disturbed until the adhesive has solidified.
4.3 Application Procedure for Cold Applied Tapes
4.3.1 Cold applied joint protection tape shall be of the type, which can be applied by spiral wrapping
on the pipe.
4.3.2 Immediately after the completion of surface preparation, the approved primer of wet film
thickness 150 microns or as per manufacturer's recommendation whichever is higher, to cover
the exposed bare metal of the welded field joint and 10 mm min. onto the adjacent pipe coating
if recommended by the manufacturer. Any dirt on the primed surface shall be removed. If the
primer is damaged, the damaged area shall be cleaned and re-primed.
4.3.3 Approximately 100 mm of inner wrap interleaving paper shall be peeled back and inner wrap
shall be applied with the thicker adhesive side to the pipe. Whilst continuously removing the
interleaving paper, the tape shall be spirally applied through a machine to provide a minimum
of 55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air
pockets and also continuously smooth out as the wrapping proceeds. The wrapping shall start

0511fazre7ah ENONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA LIMITED
Igar fafieg115 FOR FIELD JOINT COATING 6-71-0044 Rev. 3
'"""
IA God of WM Unciertanng) (ONSHORE PIPELINE) Page 10 of 12
and finish to give a minimum 50 mm overlap on to the adjoining yard applied coating. Outer
wrap shall also be applied in similar method.
4.4 Pre-Qualification of Field Joint Coating System
The field joint coating system materials and the procedures proposed by the Contractor shall be
pre-qualified during the sleeve installation start-up phase. Five joints (5) shall be coated with
the requirements of this specification and then inspected and tested in accordance with the
requirements of this specification with respect to the following:
Surface preparation, cleanliness, roughness profile and dust contamination

Pre-heat temperature (as applicable)
Primer thickness
As applied coating thickness
Holiday detection
Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and at over
laps (as applicable). If required to achieve the temperature of (+) 60°C, suitable thermal
blanket may be used.
(vii) Visual appearance and void after installation on the body, area adjoining the weld and
area adjoining the factory applied coating. (To establish voids adjoining the weld and
factory coating, a strip of 50 mm wide and 200 mm long shall be stripped and
examined.)
Company Representative shall witness the tests and inspection. Regular application of field
joint coating shall commence only upon successful completion of the pre-qualification testing.
After successful completion of the pre-qualification testing as above, the entire field joint
coating shall be removed, the pipe surface re-blasted and field joint coating re-applied as per
the requirements of this specification.
Visual inspection of the as applied coating shall be carried out on every joint, for the following:
Mastic extrusion on either ends of the sleeve shall be examined

There shall be no sign of punctures or pinholes or bend failure. The external
appearance of the sleeve shall be smooth, free of dimples, air entrapment or void
formation. All sleeves shall be tested for the presence of voids by knocking on the
sleeves. A hollow sound compared to the remainder of the sleeve may indicate the
presence of voids under the sleeve. Such sleeve shall be tested for adhesion at the
discretion of the Company Representative.
Weld bead profile shall be visible through the sleeve
Visual indicator provided on the backing and the closure patch showing desired heat is
achieved.
5.2 Holiday Inspection
The entire surface of each joint shall be inspected by means of a full circle holiday detector
approved by Company, set to a DC voltage applicable as per the requirements of factory
applied mainline coating specification of Company. Inspection of the sleeves shall be
conducted only after the joint has cooled below 50°C. The holiday detector used shall be
checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in
direct contact with the surface of coating to be inspected.

ENGINEER.S
lag elaruief UMITED

Govl of India underlaying)
FOR FIELD JOINT COATING
(ONSHORE PIPELINE)
6-71-0044 Rev. 3
Page 11 of 12
No field joint shall be covered or lowered in the trench until it has been approved by the
Company.
5.3 As-applied Coating Thickness
Coating thickness shall be checked by non-destructive methods for each field joint. Average
thickness of the as-applied coating on pipe body shall be established based on measurements at
min. eight locations i.e four measurements on either side of the girth weld at 3, 6, 9 & 12
O'clock positions. To establish the minimum thickness on the girth weld, four measurements
shall be taken on apex on the weld at 3, 6, 9 & 12 O'clock positions. All such measurements
shall be recorded. Company Representative reserves the right to ask for additional
measurements at any location on the field joint coating, whenever doubt arises.
5.4 Peel Strength Testing
5.4.1 One out of every 50 joint coatings or one joint coating out of every day's production, whichever
is stringent, shall be tested to establish the peel strength on steel and factory applied coating.
Contractor shall carry out such testing in the presence of Company Representative.
5.4.2 From each test sleeve selected as above, one or more strips of size 25mm x 200 mm shall be cut
perpendicular to the pipe axis and slowly peeled off.
The required peel strength shall meet the requirements of this specification as applicable for (+)
23 °C or (+) 60 °C whichever is feasible. This test shall be conducted between wrapping &
metal and mill coating & between layers at overlap with joint coating (wherever applicable).
After removal of strip, the bulk of adhesive shall remain adhered to the pipe showing no bare
metal, otherwise, test shall be considered failed. The adhesive layer that remains on the pipe
surface shall generally be free of voids resulting from air or gas inclusion. In case the peel
strength test at a different temperature than that specified is warranted due to the ambient site
conditions, then the peel strength shall comply the recommendation of the manufacturer.
Manufacturer shall be asked to furnish peel strength values corresponding to various expected
temperatures, prior to start of the works.
5.4.3 If the sleeve does not meet the requirements of clause 5.4.2, the adjacent two sleeves shall also
be tested. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve
every twenty five until Company's Representative is satisfied. The test rate can then be reduced
as per clause 5.4.1 at discretion of Company's Representative. If either or both of the adjacent
two sleeves do not meet the requirements of clause 5.4.2, the field coating shall be stopped.
5.4.4 Company Representative reserve the right of 100% removal of sleeves if he is not convinced
that the requirements of clause 5.4.2 are achieved.
6.0 REPAIRS
6.1 If a field joint is detected to be unacceptable after testing as per section 5.0 of this specification
the Contractor shall, at his own cost:
Determine the cause of the faulty results of the field coating.

Mobilise the expert of manufacturer, if required.
Test to the complete satisfaction of Company, already completed field coatings.
(iv) Stop the field coating works until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the Company.
6.2 Contractor shall replace all joint coating found or expected to be unacceptable as per section
5.0 of this specification.

lalfte?fila ENGINEERS
Ita 1d15Ieg WIle INDIA LIMITED FOR FIELD JOINT COATING 6-71-0044 Rev. 3
6.3 Contractor shall, at his own cost repair all areas where the coating has been removed for testing
by the Company.
6.4 After the coating work on welded joints and repairs to the coating have been completed the
coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline.
6.5 Company shall be entitled to check the coating on buried pipelines or parts of pipelines with
equipment such as the "Pearson Meter" and the resistance meter. If coating defects are
established, the Contractor shall be responsible for excavation at such points, repairing the
coating, spark testing and backfilling the excavations without extra charge.
7.0 DOCUMENTATION
7.1 Prior to procurement of coating materials, Contractor shall furnish the following information
for qualification of the Manufacturer and material:
Complete information as per clause 3.2 and DIN EN 12068 alongwith descriptive
technical catalogues.
Test certificates and results of previously conducted tests, for all properties listed in
clause 3.2 of this specification.
c. Reference list of previous supplies, in last 5 years, of the similar material indicating the
project details such as diameter, quantity, operating temperature, year of supply,
project name, contact person and feed back on performance.
Once the Company's approval has been given, any change in material or Manufacturer shall be
notified to Company, whose approval in writing of all changes shall be obtained before the
materials are manufactured.
7.2 Prior to shipment of materials from the Manufacturer's Works, Contractor shall furnish the
following documents:
Test certificates/results as per Manufacturer's Quality Control Procedure for each batch
of materials.
Specific application instructions with pictorial illustrations.
c. Specific storage and handling instructions.

an t
pkgs,,, s ENGINEER s STANDARD SPECIFICATION FOR
iNDIA umfrED CONCRETE WEIGHT COATING OF
eIMPWFOM) .Go, ot India Undeaalungl ONSHORE PIPELINES
6-71-0046 Rev. 4
Page 1 of 12
as. • n
Clal ch5hle Aliff
# Trriw feer
FOR
CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
4 23-04-12 REVISED & REISSUED AS STANDARD

SPECIFICATION NR SKJ VM DM
SPECIFICATION MKM VM AS VC
SPECIFICATION MKM KKS SJ GRR
SPECIFICATION PKG TBG VC AS
0 09-06-89 ISSUED AS STANDARD SPECIFICATION MK GD/RKD SA RCPC
Standards Standard
Rev. Prepared Checked Committee s Bureau
No by by
Approved by

amadak ENGINEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
51g-ar INDIA UMITED CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
6-71-0046 Rev. 4
IA GoN at Vida Undenakong)
Page 2 of 12
Abbreviations:

IS Indian Standard

Mr. Raj Kumar
Mr. M. S. Gunjiyal
Mr. R. Chaudhary (SMMS)

laid ENGINEERS CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
IgLIT ,
09eg INDIA LIMITED
IA Gon ONSHORE PIPELINES
ot india underusim Page 3 of 12
CONTENTS
1.0 SCOPE 4
3.0 MATERIALS 5
4.0 COATING REQUIREMENTS 6
5.0 APPLICATION METHOD 6
6.0 EQUIPMENT 6
7.0 MEASUREMENTS AND LOGGING 7
8.0 PROCEDURE QUALIFICATION 7
9.0 APPLICATION OF REINFORCEMENT AND CONCRETE COATING 8
10.0 TOLERANCES 10
11.0 WEIGHING 10
13.0 REPAIRS 11
14.0 MARKING 11
15.0 HANDLING, UNLOADING, STORING AND TRANSPORTATION 12

afazre? ENGINEERs STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
a-ell iaglegW INDIA LIMITED ONSHORE PIPELINES
IA Got/ of Mao Undertaking) Page 4 of 12
1.0 SCOPE
1.1 This specification covers the minimum requirements for the materials, application, inspection,
handling and other activities for external concrete weight coating of pipelines.
1.2 This specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between Company and Contractor.
1.3 Contractor shall, with care and diligency, execute the work in compliance with all laws, by-
laws, ordinances, regulation, etc. and provide all services and labour, inclusive of supervision
thereof, all materials, excluding the materials indicated as Company supplied materials in the
CONTRACT, equipment, appliances or other things of whatsoever nature required in or about
the execution of the work, whether of temporary or permanent nature.
1.4 Unless otherwise specified, all sections of this specification shall apply to all the specification
referred in this specification.

2.1 Reference has been made in this specification to the latest edition (edition enforce at the time
of issue of enquiry) of the following codes and specifications:
ASTM A-82 Specification for Steel Wire, Plain, for concrete

Reinforcement.
ASTM A-185 Specification for Steel Welded Wire Fabric, Plain, for
Concrete Reinforcement
ASTM A-641 Specification for Zinc Coated (Galvanized) Carbon Steel
Wire.
ASTM C-39 Test Method for Compressive strength of cylindrical
concrete specimens.
ASTM C-138 Test Method for Unit weight, Yield and Air Content of
Concrete.
ASTM C-309 Specification for Liquid Membrane Forming Compounds
for Curing Concrete.
ASTM C-642 Test Method for Specific Gravity, Absorption and Voids
in Hardened Concrete.
IS-383 Indian Standard Specification for Coarse and Fine
Aggregates from Natural Sources for Concrete.
IS-516 Method of Test for Strength of concrete.
IS-1199 Method of Sampling and Analysis of Concrete.
k) IS-8041 Indian Standard Specification for Rapid Hardening
Ordinary Portland Cement.
I) IS-8112 Indian Standard Specification for 43 Grade Ordinary
Portland Cement.
IS-2386 (Parts-I : Indian Standard Methods of Test for Aggregates for
thru' VIII) Concrete.
IS-12269 Indian Standard Specification for 53 Grade Ordinary
Portland Cement.

SafaeleTe ENGINEERS CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
Sig-a laiReg INDIA LIMITED ONSHORE PIPELINES
imenew.w=ano ,,Geri of Meta linden...91 Page 5 of 12
In case of conflict between the requirements of this specification and that of the above referred
codes and standards, the requirements of this specification shall govern. The Contractor shall
be familiar with the requirements of these documents and shall make them readily available at
the coating plant.
2.2 For the purpose of this specification, the following definition shall hold:
the words 'Shall' and Must' are mandatory;

the words 'Should', 'May' and 'Will' are non-mandatory, advisory or recommended.
3.0 MATERIALS
3.1 The Contractor shall supply all the materials necessary for the performance of the work.
Materials for concrete weight coating shall comply with the following requirements. All the
materials supplied by the Contractor, which in the opinion of Company's
Representative/Inspector, do not comply with the appropriate specifications, shall be rejected
and removed from the site.
3.2 Cement
Ordinary Portland Cement (conforming to IS-8112/ IS-12269) shall be used. Cement which
has hardened or partially set or which has become lumpy shall not be used. Test certificates
from the cement Manufacturer shall be supplied to the Company for all cement delivered to
site.
In case concrete weight coating is to be provided at locations affected by sea water tidal flats
etc., Portland cement in accordance with ASTM C-150 Type III or IS-8041 shall be used.
3.2 Aggregates
3.2.1 Aggregates shall comply with the requirements of IS:383 and shall be tested in accordance
with IS:2386.
3.2.2 Fine Aggregates
`Fine Aggregates' shall mean any of the following, as defined in IS:383:
Natural sand;
Crushed stone sand;
iii) Crushed gravel sand.
Sand shall be well graded from fine to coarse in accordance with Table 4 of IS:383.
3.2.3 Coarse Aggregates
Use of coarse aggregates shall be subject to Company approval.
3.2.4 Aggregates (fine and coarse) shall be clean and free from clay and injurious amounts of salt,
alkali, deleterious substances or organic impurities.
3.3 Water
The water shall be fresh and clean and shall be free from injurious amounts of oils, acids,
alkalis, salts, sugar organic materials or other substances that may be deleterious to concrete
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL — All rights reserved

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No
O ENGINEERS CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
Rateg INDIA LIMITED ONSHORE PIPELINES Page 6 of 12
or steel. It shall not contain chlorides, sulphates, and magnesium salts. Water from each source
shall be tested prior to its use and shall be approved by Company. Seawater or contaminated
water shall not be used. Water from doubtful sources shall be tested by the Contractor at his
expense and approved by Company before use.
3.4. Reinforcement
Concrete coating shall be reinforced by a layer or layers of steel reinforcement according to

the provisions hereinafter described.
3.4.1 Reinforcement shall consist of welded steel wire fabric manufactured in flat sheets or in rolls
(ribbon mesh) and shall conform ASTM A-185. Wires shall conform to ASTM A-82.
3.4.2 Steel wire shall be galvanised at finished size as per ASTM A-641. The diameter of the wire
and spacing of wires (mesh dimensions) shall be selected according to the following criteria.
3.4.2.1 Wire fabric manufactured in flat sheets shall be 2 x 4 inches max. Steel wire mesh, 13 gauge
U.S. Steel wire (2.4 mm) min. each way.
3.4.2 2 Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. Steel
wires (2mm wire). The above dimensions will be applied unless otherwise specified by
designs. As a rule wire fabric (sheets) shall be used when concrete coating is applied by
casting method, while ribbon mesh (rolls) shall be used when concrete coating is applied by
impingement method.
4.0 COATING REQUIREMENTS
Pipes shall be concrete coated to a thickness and density as specified in the drawings and
CONTRACT documents. The concrete unit weight shall be minimum 2245 kg/m (140
pounds per cubic foot) and the compressive strength shall not be less than 250 kg/cm 2 in 28
days and 165 kg/cm2 in 7 days. Concrete coating shape shall be circular and concentric to pipe
outside diameter. Other concrete coating shapes are not acceptable.
5.0 APPLICATION METHOD
Concrete coating shall be applied either using casting or impingement method. Any alteration
or modifications to the methods described in this specification shall be submitted to the
Company for approval. The application method shall however ensure the basic characteristics
of concrete coating in compliance with the minimum requirements of this specification.
Contractor shall submit to the Company, prior to commencement of work, the

procedure/method of application for approval.
Wherever practical, the total thickness of coating shall be applied in a single pass.
6.0 EQUIPMENT
The equipment used for performing the concrete coating shall be capable of doing so with a
required degree of uniformity with respect to thickness, density and strength. The
proportioning equipment and procedure shall be of the type to assure consistently
proportioned material by weight. Concrete shall be mixed in a mechanical mixer, which shall
ensure thorough mixing of all materials. Any equipment that tends to separate the ingredients
shall not be used. Ready mixed concrete supplied by ready-mixed concrete plant shall be
preferred.

45ifaeietlah ENGNEERS
4gesernireWeeilif
t
INDIA LIMITED CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
6-71-0046 Rev. 4
niavimo IA Govt of India Underlakingl Page 7 of 12
7.0 MEASUREMENTS AND LOGGING
7.1 All measurements as mentioned below shall be taken during the work stages and clearly
logged in a logbook. A special logbook shall be used for recording tests and trial results. A
logbook shall refer to pipe lengths having the same nominal diameter, and steel wall thickness.
7.2 The following shall be subject to measurement and logging for each pipe length.
a) Line Pipe
1) Field identification number (F)

2) Mill serial number (M)
3) Length (L)
4) Weight (BW)
5) Outside diameter, mm & Wall Thk, mm (OD) / (WT)
b) Corrosion coating
Type of coating (C)

Thickness of corrosion coating, mm (CT)
Weight of coated pipe, kg (CW)
Presence of anode (Yes or No) (A)
Date of Corrosion Coating Application (DCC)
c) Concrete Coating
Batch identification number (B)

Date of placing the concrete coating (T)
Average concrete coating thickness, mm (CCT)
"Dry Weight" of concrete coated pipe (DW)
(Weight and date of weighing or
Related Weight 28 days after placing
of concrete and so identifiable)
"Unit dry weight" of concrete coated pipe (UDW)
"Negative Buoyancy" (unit) of concrete (NB)
Coated pipe
Data can be obtained from Pipe Mill tally Sheets.

Data can be obtained from Coating Plant Tally Sheets.
7.3 No concrete placing shall be allowed before items 1 through 10 listed at clause 7.2, have been
logged.
8.0 PROCEDURE QUALIFICATION
Before commencement of the work, Contractor shall perform all tests, either in laboratory or
in field and trials necessary to properly select type of mix, which meets the requirements of
this specification.
8.1 The type of mix, i.e. the correct combination of the cement, aggregates and water which
results in the desired properties of concrete shall be at first determined for each mix and
following shall be accurately checked and recorded:
proportion and weights of the respective materials used;

the water/cement ratio;
the grading of the aggregates.

STANDARD
453faelel ENGINEERS WEIGHT COATING OF 6-71-0046 Rev. 4
$11ga MiegNiV INDIA LIMITED ONSHORE PIPELINES
21735,7 .W.p.") (A Gm/ o/ India Undedaking) Pa e 8 of 12
8.2 Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry
specific gravity of the concrete. In parallel, test according to ASTM C-138 shall be performed
so as to determine the expected correlation between concrete weight after placing and dry
specific gravity (28 days after placing). Test for concrete specific gravity at Intermediate time
(7 days after coating) shall be performed.
8.3 When the results of the above tests do not meet the requirements, the mix shall be modified
and concrete samples tested until a proper mix has been determined.
8.4 The mix so determined, shall then be used for sampling of concrete to be submitted to
compressive strength tests as per ASTM C39 or IS-516.
8.5 Frequency of sampling for tests for density and compressive strength of concrete shall be as
follows:
3
"Quantity" of Concrete in the Work (m ) Number of samples
Upto 25 3
26 to 50 4
51 and above 4 plus one additional
sample for each
additional 50 m3 or
part thereof
`Quantity' means the volume of concrete to be used for each qualified mix.
9.0 APPLICATION OF REINFORCEMENT AND CONCRETE COATING
9.1 Two test cubes each per day shall be obtained from batches and tested at the end of 7 days
after coating, for compressive strength and specific gravity.
9.2 The moisture content of the aggregates used shall be such as to maintain a satisfactory control
on the water/cement ratio of the concrete mix.
To maintain the water/cement ratio constant at its correct value, determination of moisture
contents in both fine and coarse (if used) aggregates shall be made as frequently as possible,
the frequency for a given job being determined by the Engineer-in-Charge according to
weather conditions.
9.3 Pipe Length Preparation
Prior to placing of reinforcement, the anti-corrosion coating of each pipe length shall be
carefully inspected visually and by holiday detectors and, if damages are found, they shall be
repaired in accordance with the relevant specification, before start of the work. Foreign
matters, if any, shall be removed from the surface of the anti-corrosion coating.
9.4 Reinforcement Application
9.4.1 Reinforcement shall be placed around the pipe in such a way as to cover the whole pipe length
or sections to be concrete coated. The reinforcement shall not protrude beyond the concrete
coating ends.
9.4.2 Reinforcement shall rest on synthetic resin spacers forming a "Crown" whose number shall be
such as to avoid any contact with the pipe's protective coating. Spacing between the two
consecutive "crown" centres shall be 500 to 1000 mm.

lsimile?at ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
$1g-elaiRn
l 01 54aU WI INDIA
ereanzenjapr)
LIMITED
(A Goy/ of 1riaa Undenalon91 ONSHORE PIPELINES Page 9 of 12
9.4.3 Splices and attachments shall be done by binding with steel wire having 1.5 mm diameter.
Circular and longitudinal joints of wire fabric in sheets shall be lapped at least for one mesh.
When wire fabric in rolls (ribbon mesh) is used, the spiral lap shall be one mesh while spliced
lap shall be three meshes.
9.4.4 One layer of reinforcement steel shall be provided for concrete thickness less than 50 mm. The
reinforcing steel shall be embedded approximately midway in the concrete coating thickness.
For concrete thickness 50 mm and above two layers of reinforcing steel shall be provided. If
application method requires more than one pass concrete, one reinforcement layer for each
pass is to be applied independently from concrete coating thickness.
In case of one layer of reinforcement, it shall be located approximately in the middle of the
concrete thickness. In case of two layers of reinforcement, layers shall be located at 1/3 rd and
2/3“1 of the concrete thickness. In case of three layers of reinforcement, layer shall be located
at I/4th, 1/2 and 314th of concrete thickness. Contractor shall demonstrate that the procedure
used ensures no physical contract between steel reinforcement and the pipe and the
reinforcement is placed in position as mentioned above.
9.5 Concrete Placing
9.5.1 Concrete shall be placed within a maximum of 30 minutes from the time of mixing (i.e. after
adding water to mix) and shall be handled in such a way so as to prevent aggregate
segregation and excessive moisture loss. Concrete containers shall continuously be kept clean
and free from hardened or partially hardened concrete.
9.5.2 If casting method is used, once reinforcement and mould have been applied around the pipe,
concrete mixture shall be poured through an opening on the upper section of the same mould.
Concrete shall not be poured from a height greater than 1 metre. During pouring of concrete,
vibrator sets applied inside of pipe or outside the mould shall vibrate the mix so as to obtain
the best possible compactness.
9.5.3 If impingement method is used, placement of concrete shall be upto the specified thickness in
one continuous course, allowance being made for splices of reinforcement and providing
reinforcement in the right location. Concrete shall be projected at high velocity against the
external surface of pipe, to produce a hard, tight-adhering coating of the specified thickness.
9.5.4 No casting shall be interrupted or passes shall be stopped for more than 30 minutes. Before
placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and
wetted to obtain a good bond between the fresh material and the previously placed material.
9.5.5 Suitable means shall be provided to ensure that the temperature of the concrete, when placed,
does not exceed 32°C.
9.5.6 All pipes shall be kept clean and free from cement concrete and grout either inside or outside
of the uncoated sections.
9.5.7 Bevel protectors shall be kept in place throughout the coating application and after.
9.5.8 The coating at each end of the pipe shall be bevelled to a slope of approximately two-to-one
(2:1). It shall terminate about 50 mm short of the end of the corrosion coating applied on the
pipe surface.
9.6 Curing
9.6.1 Immediately after concreting, the exposed surfaces of the concrete shall be protected during
hardening from the effects of sunshine, drying winds, rain, etc. and then after the initial set has

sitmzE?Atith ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
RaleettrINDIA LIMITED ONSHORE PIPELINES
Gmi of Innedaking) Page 10 of 12
taken place, the concrete coating shall be properly cured. The coated pipe sections shall be
handled gently by suitable means to prevent undue distortion.
9.6.2 Curing shall be performed by application of an approved curing membrane using sealing
compounds and shall meet the requirements of ASTM C-309. The material shall be stored,
prepared and applied in strict conformity with the instructions of the Manufacturer. The
ingredients of any such compound shall be non-toxic and non-inflammable and shall not react
with any ingredient of the concrete, the reinforcement, protective coating or pipe. The
application of the curing compound shall take place immediately after the coating is
completed and preferably before the pipe is removed from the concrete coating apparatus. The
surface of the concrete shall be lightly sprayed with water before applying the curing
compound. The membrane curing period shall not be less than 4 days, during which period the
freshly coated pipes shall not be disturbed. The pipe surface shall be kept wet during daylight
hours for seven days after application of the concrete coating. The concrete coating shall not
be allowed to dehydrate.
Curing of concrete coating may also be done by using jute bags, provided continuous wetting
is ensured by the Contractor.
9.6.3 Before handling and hauling the concrete coated pipes, a check shall be made to make sure
that the concrete coating is properly cured. Stacking and shipment of the coated pipe shall be
initiated only after seven days provided that the concrete coating suffers no damage.
10.0 TOLERANCES
10.1 Contractor shall maintain a surface tolerance of 8 mm (5/16") maximum for the radial distance
between high and low areas of the surfaces. The diameter of each coated pipe shall be
obtained at three (3) or more points, spaced at equal intervals between the end points.
10.2 The acceptable weight tolerance for any single pipe shall be limited to plus five (5) or minus
two (2) percent of the calculated theoretical weight. The theoretical weight shall be calculated
using total weight of the pipe with concrete and corrosion coating.
10.3 The acceptable weight tolerance of any single pipe shall be limited to +5% or -2% of the
calculated weight of concrete. Calculated weight shall consider only the weight of concrete
coating based on approved concrete density and thickness.
11.0 WEIGHING
11.1 The test specimen shall be selected at equal intervals during the course of production.
11.2 Contractor shall weigh each pipe when dry prior to shipment and 28 days after placing of
concrete and mark the weight with paint on the inside of the pipe. The weight mark shall be
followed with letters "DW" meaning Dry Weight.
11.3 In case Contractor opts not to weigh the pipes, the Contractor shall provide 20% extra
concrete coating thickness over the specified concrete thickness at no extra cost and time to
Company.
12.1 After curing, every length of concrete coated pipe shall be non-destructively tested by means
such as "ringing" to determine if any suspected defects are present. In case this indicates
faulty coating, cores shall be removed from coating and inspected. When defective coating
appears from cores, the concrete coating shall be removed from the pipe lengths.

lorTh
5,g46-il eieVEND NGIIANEE LJASTED CONCRETE WEIGHT COATING OF 6-71-0046 Rev. 4
wen owenwmarran AGo„ of Vida Undelta10.91 ONSHORE PIPELINES Page 11 of 12
12.2 Every length of concrete coated pipe shall be checked to verify insulation between steel
reinforcement and pipe by means of a megger or equivalent device. To this purpose provisions
should be made during placing of concrete such as to leave at least a point of exposed steel
reinforcement whenever the latter shall terminate inside of concrete coating.
12.3 During the tests as per clause 12.2 above, and before transporting of concrete coated pipes,
every pipe length shall be visually inspected to detect whether any damages and/or defects are
present. Possible damages and/or defects with their allowable limits are described at following
clause 13.0. Repairable concrete coatings shall be clearly marked while the non-repairable
once shall be removed from the pipe lengths.
13.0 REPAIRS
The following repairs are permitted to coating due to unavoidable damage in handling and in
storage (This applies only to concrete that has hardened).
13.1 Spalling due to compression or shearing caused by impact against other objects. Spalling is
defined as damage, which causes a loss in concrete of more than 25 % of the total thickness of
the coating at the point of damage.
13.2 Damage due to spalling of an area of less than 0.1 m2 (1 square foot) where the remaining
concrete is sound and reinforcement steel is not exposed, will be accepted without repairs.
Total damage area in one pipe joint shall not exceed 0.1 m2.
13.3 Damage due to spalling of an area of less than 0.1 m2 with reinforcement exposed; and area
more than 0.1 m2 and less than 0.3 m2 shall have the concrete remaining in place over that area
removed as necessary to expose the reinforcing steel throughout the damaged area. Edges of
the spalled area shall be under-cut so as to provide a key lock for the repair material. A stiff
mixture of cement, water and aggregate shall be trowelled into and through the reinforcement
and built up until the surface is level with the coating around the repair. The pipe shall then be
carefully laid with the repaired area at the top and shall be moist cured for a minimum of thirty
six (36) hours before further handling.
13.4 Should the damaged area be more than 0.3 m 2, coating shall be removed around the entire
damaged area. A repair shall be made by satisfactorily restoring the reinforcement, forming
the area with a metal form and pouring a complete replacement of materials similar to that
from which the coating was made. The mixture shall be one (1) part of cement to three (3)
parts of aggregate and the necessary water to produce a slump not to exceed 100 mm (four
inches). The resulting coating shall be equal in weight, density, uniformity, thickness, strength
and characteristics to the originally applied coating. The pipe shall then be carefully laid in a
position where it shall be allowed to remain for a minimum of 36 hours before further
handling.
14.0 MARKING
14.1 Every concrete coated pipe length shall be clearly marked by a suitable type of paint (i.e. red
and/or white lead paint). Markings of concrete coating shall be made inside of pipe close to
bevel end, in such a way that the area involved by welding operations is not affected by paint.
14.2 For each concrete coated pipe length, at one of the two ends, the field identification number
and the date of concrete placing shall be marked, while the dry as well as the wet weight along
with number of days after coating shall be marked at the other end. In addition, Contractor
shall develop a colour coding (band) system to be marked on the outside surface for easy
identification of the coated pipe for each concrete coating thickness, concrete density, pipe
diameter, pipe thickness and pipe material variation.

4elENNGIDIANEELIMRSTED
FIRM Jv0.0 GOvl Of
I
India undePlaking)
CONCRETE WEIGHT COATING OF
ONSHORE PIPELINES
6-71-0046 Rev. 4
Page 12 of 12
15.0 HANDLING, UNLOADING, STORING AND TRANSPORTATION
15.1 Once the pipe sections have been taken on charge, the Contractor, complying with provisions
of the CONTRACT, shall execute their transport together with other material, either supplied
by him or by the Company, from the site of receipt to the coating yard and after concrete
coating completion and acceptance, to delivery point at laying field or storage areas as
previously established providing each time the necessary storages.
15.2 Materials other than pipes and which are susceptible of deteriorating or suffering from
damages especially due to humidity or other adverse weather conditions, shall be suitably
stored and protected.
15.3 During loading, transport, unloading and hauling of inert aggregates, any contact and mixing
with mud, earth, grease and any other foreign material shall be carefully avoided. Precautions
shall be taken to prevent contamination, to maintain the cleanliness and against effects of hot
or cold weather or other adverse climatological condition.
15.4 During the operations of loading, unloading and stock-piling, the pipe sections shall be
handled in such a way so as to avoid dents, cuts, cracks and other damages especially at
bevelled ends or damages to protective and/or concrete coating.
15.5 Stacks shall consist of a limited number of layers such that the pressure exercised by the pipes
own weight does not cause damage to coating. Stacking with more number of layers shall be
agreed upon with the Company provided that each pipe section is separated by means of
spacers suitably spaced so as to avoid stresses and compressed points of contact on the coated
surfaces.

laifiladdilft ENGINEERS FOR REPAIR OF
ligTjr EIMegilet INDIA UMITED 6-71-0048 Rev. 1
aorop 1,,erwe =praying) IA Gout of Ma tfildettaling) POLYETHYLENE COATING Page 1 of 6
iftWermtff A-crff -gRnTff

1-4-4RT
FOR REPAIR OF
POLYETHYLENE COATING
■‘\ •
•
1 16.05.12 REVISED AND REISSUED AS STANDARD - VM DM
SPECIFICATION SKJ
0 29.10.07 ISSUED AS STANDARD SPECIFICATION MKM VM AS VC

Standards Standards
No by by
Approved by

lea ENGINEERS FOR REPAIR OF 6-71-0048 Rev. 1
51g7ElfWleGrIBF INDIA LIMITED POLYETHYLENE COATING
allen 2120W all 370+.1) IA Govt a S Undenakingi Page 2 of 6
Abbreviations:
DC Direct Current
EN European Standard
KV Kilo Volt
Members: Mr. S K Jain

Mr. Raj Kumar
Mr. M. S. Gunjiyal

FOR REPAIR OF 6-71-0048 Rev. 1
POLYETHYLENE COATING Page 3 of 6
CONTENTS
1.0 SCOPE 4
2.0 MATERIAL AND EQUIPMENT 4
3.0 APPLICATION PROCEDURE 4
4.0 INSPECTION AND TEST 5
5.0 DOCUMENTATION 6

01Wide) ENGINEERS FOR REPAIR OF
LII EIVieg e INDIA LIMITED
6-71-0048 Rev. 1
IA Gov, af India Lindedsingj POLYETHYLENE COATING Page 4 of 6
1.0 SCOPE
This specification covers the minimum requirements for materials and equipment, application
procedure and inspection of repair of damaged Polyethylene coatings on steel pipes. This
specification is applicable for repairing damages less than 100mm x 100 mm for pipe sizes
less than 10", 150mm x 150mm for pipe sizes between 12" to 28" and 300mm x 300mm for
pipe sizes more than 28".
If damaged area of coating of the pipeline is larger than above, heat shrinkable sleeve is
recommended.
The repair shall be carried out using repair patch made of radiation cross-linked polyolefin
backing, coated on the inside with semi-crystalline thermoplastic adhesive and filler mastic.
The repair patch shall have thermal indicators to ensure correct heat is being applied during
application.
2.0 MATERIAL AND EQUIPMENT
2.1 The repair material shall be as under:
Repair Patch: radiation cross-linked HDPE (Unexpanded High density polyethylene)

with semi-crystalline thermoplastic adhesive (PERP80 of make Covalence Raychem
or equivalent).
Filler Mastic: PERPFILLER of make Covalence Raychem or equivalent.
PERP melt stick of make Covalence Raychem or equivalent
Liquid Epoxy Primer (two pack)
2.2 The repair material shall be certified by DIN to meet the requirements of ENI2068 Stress
Class CHT 80
2.3 The material shall not be older than their period of validity at the time of application by the
Contractor. Deteriorated/decomposed materials shall not be used.
2.4 Materials shall be stored in sheltered storages in the manufacturer's original packing away
from direct sunlight and in accordance with manufacturer's instructions.
2.5 Contractor shall supply all equipment and manpower required for a skillful application in the
field in accordance with the specification.
3.0 APPLICATION PROCEDURE
3.1 The application procedure to be followed for holiday type of damage shall be in accordance
with manufacturer's instruction and minimum requirement specified below whichever are the
more stringent.
3.1.1 Preparation
Remove coating from damaged area with knife, scraper or power brush. Scrap of the
damaged area and adjacent coating to remove oil, grease, rust, dirt and moisture. Pipe surface
shall be prepared to SA 21/2.

ISillikEqeENONEERS
51fgar Etwee INDIA LJMITED
FOR REPAIR OF
POLYETHYLENE COATING
6-71-0048 Rev. 1
IA GOA 01 MO. Undertaktigl
Page 5 of 6
3.1.2 Preheating
Preheat the exposed bare metal surface to approx. 80° C and adjacent pipe coating to approx.
60° C with a torch moved back and forth over the surface. Upon preheating, the pipe surface
shall be applied with the two pack epoxy primer to ensure a minimum wet film thickness of
not less than 200 microns to cover the exposed base metal.
3.1.3 Application of the Filler
Plastic filler shall be cut to size and applied to all exposed metal surface. The mastic shall be
heated and smoothed down with a paint scraper to cover all bare metal in a manner such that
all entrapped air is removed and mill applied coating thickness of the pipe is restored.
3.1.4 Application of repair tape
A patch shall be cut from the tape in a manner such that it extends 50 mm (2 inch) beyond the
damaged area on all sides. The patch shall be positioned over the damaged area and heated
until the temperature sensitive paint on the outside of the patch changes colour or dimples on
the backing vanish. It shall be smoothed down to confirm with the contour of lap, and shall be
freed of any air bubbles or wrinkles.
3.2 For cosmetic type of defects such as minor gouging, tearing, and/or scratches, which do not
indicate holiday during holiday inspection, following procedure shall be adopted.
3.2.1 The defective area shall be roughened to remove loose polyethylene coating, oil, grease, dirt,
etc.
3.2.2 This shall be followed by application of patch as detailed in clause 3.1.4.
4.0 INSPECTION AND TEST
4.1 A visual inspection shall be carried out for the following:
Mastic extrusion on ends of the patch shall be examined.
There shall be no sign of punctures or pinholes or bend failure. The external

appearance of the patch shall be smooth, free from dimples, air entrapment or void
formation.
The entire closure patch shall have changed colour uniformly.
4.2 Holiday Inspection
The holiday detector used shall be checked and calibrated daily with an accurate D.C.
Voltmeter. The detector electrode shall be in direct contact with the surface of coating to be
inspected.
The entire surface of the repaired section shall be inspected by means of a full circle holiday
detector approved by Owner set to a D.C. Voltage of at least 25 KV. Inspection of repaired
patch shall be conducted only after it has cooled below 50° C.
4.3 Procedure qualification shall be carried out for repair patch. The value for peel strength to pipe
surface and to factory coating carried out as per EN 12068 shall be 0.5 N/mm minimum at
60°C.
4.4 All repaired joint shall be approved by the Owner.

FOR REPAIR OF 6-71-0048 Rev. 1
POLYETHYLENE COATING Page 6 of 6
5.0 DOCUMENTATION
5.1 Prior to procurement of coating repair materials, Contractor shall furnish four copies of, but
not limited to, the following for qualification of the Manufacturer and material:
Complete descriptive technical catalogs describing the materials offered along with
samples of repair coating materials, its properties and installation instruction as
applicable specifically to the project.
Test certificate and results of previously conducted tests from independent inspection
agency, for properties listed in Para 4.3 of this specification.
iii) Reference list of previous supplies of the similar material indicating the project details
such as diameter, quantity, service conditions, year of supply, project name, contact
person and feed back on performance.
Once the Company's approval has been given, any change in material or Manufacturer shall be
notified to Company, whose approval in writing of all changes shall be obtained before the
materials are manufactured.
5.2 Prior to shipment of materials from the Manufacturer's works, Contractor shall furnish six
hard copies and an electronic copy of the following:
Test certificates for each batch of materials.
Specific installation instruction with pictorial illustrations.
iii) Specific storage and handling instructions.

INDI NEERS
(AIM =MOM
ENGIA
LIMIT CONSTRUCTION OF PIPELINES
EDCROSSING ROADS, RAIL ROADS &
(A Govt Inds Undertoking)
MINOR WATER CROSSINGS

6-71-0052 Rev. 3
Page 1 of 11
criztiql1 WEFT
VA* iff‘
1:rriW ?elk
STANDARD SPECIFICATION FOR
CONSTRUCTION OF PIPELINES
CROSSING ROADS, RAIL ROADS AND
\k-oP
RE-AFFIRMED & REISSUED AS STANDARD
3 09.05.11
SPECIFICATION NR VM DM
2 22-03-06 VJN
SPECIFICATION MKM SK AS
1 28.9.98 SPECIFICATION KKS RK VC AS
0 09.06.89 ISSUED AS STANDARD SPECIFICATION MK GD SA RCPC

Standards Standards
No Date Purpose Convenor Chairman
by by
Approved by

eit'idgith ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
41 en
g
lawn
tmegvir
21■RIAZ0. 3cM.i)
INDIA LIMITED CROSSING ROADS, RAIL ROADS &
(A Govt ot India Undertaking)
MINOR WATER CROSSINGS Page 2 of 11
Abbreviations:

OISD Oil Industry Safety Directorate
RoU Right of Use
US DOT United States Department Of Transportation
Convenor: Mr. Vinay Mittal
Members: Mr. Raj Kumar

Mr. M. S. Gunjiyal
Mr. Atul Chhatwal
Mr. A.K.Chaudhary (PDD)
Mr. M.P.Jain (Projects)

ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
1W114:31A umnID CROSSING ROADS, RAIL ROADS &
2:11=
Men MOW =WOO IA Govt. el Inch Undated%)
Page 3 of 11
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS 4
3.0 GENERAL 5
4.0 ROAD AND RAIL-ROAD CROSSINGS 6
5.0 CROSSING OF BURIED SERVICES 9
6.0 MINOR WATER COURSE CROSSINGS 9

-

4oi 21 igh ENGINEERS CONSTRUCTION OF PIPELINES
`fgzlf161P-eg WV INDIA LIMITED CROSSING ROADS, RAIL ROADS & 6-71-0052 Rev. 3
lonirrardnn'fril3OrffAi (A Govt of India Undertaking)
1.0 SCOPE
1.1 This specification covers the minimum requirements for the various activities to be carried out
by the Contractor for or about the installation of pipelines crossing roads, railroads, minor
watercourses and other services.
The provisions of this specification are not applicable for pipelines crossing water courses,
which are specifically designated as "Major Water Courses" in the CONTRACT.
documents included in the CONTRACT between Company and Contractor. Unless specified
specification.
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS
of floating the enquiry) of the following codes, standards and specifications.
ASME B 31.4 - Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids
ASME B 31.8 Gas Transmission and Distribution Piping systems.
API RP 1102 Recommended practice for Liquid Petroleum Pipelines

Crossing Railroads and Highways.
OISD B 141 Design and construction requirements for cross-country

hydrocarbon pipelines
Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line
(US DOT - Pipe Line Safety Standards).
Part 195 Transportation of liquids by Pipe Line

g) EIL Standard Specifications:
6-71-0051 Standard Specification for Pipeline Construction (Onshore)
6-77-0006 Welding Specification for Onshore Pipelines for

Transportation of Gas
iii) 6-77-0007 - Welding Specification for Onshore Pipelines for

Transportation of Liquid Hydrocarbons
2.2 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern. In case of conflict
between the requirements of this specification and that of the above referred codes, standards,
specifications and practices, the requirements of this specification shall govern.
2.3 For the purpose of this specification the following definitions shall hold:
the words 'Shall' and 'Must' are mandatory.


ENalistraED
fb iN CR OSNSSIT
CO NR CO
GUR TA IPREO
IODNSOF PL LIANDESS
6-71-0052 Rev. 3
&
Page 5 of 11
MIRA PROWMIJAIIIVII (A Goof of MOW Undotaldno
3.0 GENERAL
3.1 Crossing of roads, railroads, buried services, canals and minor water courses with equipment
and/or personnel is allowed only after acquiring approval from the authorities having
jurisdiction and after malting arrangements for safeguarding the roads, etc. and the verges
and/or banks thereof and the buried services with appropriate provisions.
Highways, Main-Roads and Railroads and their verges and banks of water crossings are not
allowed to be used for loading, unloading or stacking of materials and/or equipment. For
secondary roads, such loading/unloading is permitted only after prior approval from the
concerned authorities. Contractor is not allowed to close or divert roads or watercourses
without prior approval from the Company and the concerned authorities. Contractor shall
never unnecessarily hamper the users of the roads, railroads, buried services and/or
watercourses. The water flow shall not be obstructed in any way.
All Civil and Mechanical works associated with or incidental to the installation of pipeline
crossings shall be carried out in accordance with EIL Specification no. 6-71-0051 "Standard
Specification for Pipeline Construction (Onshore)".
3.2 Company reserves the right to demand for individual crossings from the Contractor a separate
detailed report for approval, containing:
Approval letter from concerned authorities
Time Schedule
Execution methodology with details of equipment
Test procedure
Manpower deployment
Calculations/Description of temporary works
Design calculations for crossing
Soil investigations, etc.
Such works shall be without any extra cost to Company.
3.3 Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically pretested
ex-situ, prior to joint coating, whenever,
Crossing is executed by boring of carrier pipe:
Crossing is installed in casing pipe;
River Crossing pipes which are to be continuously concrete weight coated
Whenever, in Company's opinion, the repair of pipeline at crossing, in case of a leak

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

401 el MENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
LIIEIVRegw
wen
Mew' =WO INDIA LIMITED CROSSING ROADS, RAIL ROADS &
1A Govt Incite Undertaking)
The section of the pipeline for the crossing shall be tested as a single string. Unless specified
otherwise in the CONTRACT, the test pressure shall be the one resulting in hoop stress
corresponding to 90% of SMYS of pipe material. Test pressure shall be retained in the
pipeline for minimum period of four (4) hours. Test section shall be kept under surveillance by
regular patrols during test and it shall be visually examined for leaks/defects, etc.
4.0 ROAD AND RAILROAD CROSSINGS
4.1 The work under crossings shall include necessary clearing, grading and trenching to required
depths and widths, welding of casing (when required) and carrier pipes, lowering-in, back
filling, clean-up, restoration to the original condition and further strengthening and protective
works, testing, installation of assemblies, insulators and end-seals, and temporary works such
as sheet piling, bridges, etc.
The work shall be carried out in accordance with the approved drawings and job standards, as
directed by Company and to the satisfaction of Company and the authorities having
jurisdiction over the facility crossed. The work carried out for road and railroad crossings shall
meet the minimum requirements of API RP 1102.
Before the installation work of crossings is started, the Contractor shall provide suitable
barricades, temporary bridge/bypass work (especially where roads are open-cut) with railing,
if required by Company for safety of traffic. Adequate traffic warning signals and/or traffic
lights and suitable diversions shall be provided as directed by Company/Authority having
jurisdiction over these areas. Such diversions shall not cross the pipeline where it has already
been installed, unless proper safeguarding at Company's opinion is ensured.
Prior approval from the statutory authorities shall be obtained to lay the pipeline across the
highway/road either by boring or by open-cut method. Installation of the crossing shall be by
the method (i.e., boring/open-cut) approved by Authorities having jurisdiction. Railroad
crossings shall always be bored/jacked.
4.2 Boring/jacking of carrier pipes for crossings is allowed only if the pipes for boring/jacking are
provided with a suitable corrosion coating and Contractor remains liable for the suitability of
the pipe and weld-coating of carrier pipes to be bored and type of coating and method of
application are anyhow to be authorized by Company without prejudice to Contractor's
liability. In all other cases the carrier pipes shall be cased.
Before start of the boring/jacking operation, Contractor shall execute soil investigations and
determine the ground water table. Based on these investigations, Contractor shall prepare a
construction drawing and submit to Company for approval including time schedule and soil
investigation report.
During the execution of the boring, the ground water table over the length of the boring shall
be lowered up to atleast 0.50 m below bottom of the pipeline. This water table is to be
regularly inspected and maintained by Contractor and reported to Company. To safeguard the
stability of the bore pit, Contractor shall, if necessary in Company's opinion, use a closed
sheet piling, which shall extend atleast over 50% of the length in undisturbed soil. The length
of the boring shall be in accordance with the width of the ROU of the crossing (road, railroad,
etc.), with minimum 0 6 m extra on either side.
If the soil conditions and ground water for a particular boring give reasons for this, Contractor
is entitled to suggest to Company for a relaxation of one or more of the following
requirements as defined here forth.
Soil investigation

ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
WA LMTED CROSSING ROADS, RAIL ROADS &
Page 7 of 11
IA Gout of Ind* Urldlaitivq)
Lowering of ground water table
Sheet piling
Length of boring, etc.
In approaches to the crossing, Contractor shall eliminate unnecessary bending of pipe by

conforming to the contour of the ground by gradually deepening the ditch at such approaches
as directed by the Company.
4.3 The bottom of the trench and/or the pit for at least twelve (12) meters at the approach to each
end of a casing shall be graded and if necessary backfilled with clean sand and compacted
upto atleast 95% Proctor Density to an elevation that will provide sufficient and continuous
support to the pipeline so that the pipeline remains correctly aligned at casing ends during and
after backfilling.
4.4 The diameter of the hole for a bored section shall have a hole diameter as close as practicable
to the outside diameter of the carrier or casing pipe. If excessive void or too large hole results,
or if it is necessary, in the opinion of Company, to abandon the bored hole, prompt remedial
measures such as filling the hole with suitable material shall be taken to the entire satisfaction
of the Company and Authorities having jurisdiction thereof at no extra cost to Company.
Equipment used for installation of casing pipe shall be of the type approved by Company.
An installation consisting of hydraulic jacks shall be provided with easily readable pressure
gauges (in bar) and sealable pressure limits. Their proper operation shall be demonstrated
before the work is started. Company can request that the maximum pressing force be limited.
At the front of the pipe there may be a cutting ring, which may be 12 mm large than the
outside diameter of the pipe or casing. A lubricating pipe can also be used in jacking, the
nipples of which shall not protrude from the cutting ring. Said lubricating pipe shall not be
fixed to the pipe or casing. When jacking, only biologically degradable lubricants shall be
used (e.g. WRC Medlube or an emulsion of bentonite).
Removal of soil from the pipeline during jacking shall be done mechanically by means of a
standard, locked auger, which has to be safeguarded against jacking ahead of the pipe. If, in
the opinion of the Company, fluid sand may arise, an inner pipe with funnel shall be used.
During jacking, the progress of the pipe to be jacked and the cutting capacity of the auger shall
be mutually adjusted, by regulating the speed of auger, to prevent the road from bulging (rpm
too low) or cave-ins (rpm too high). In any case no more soil shall be removed than the
volume of the pipe. The auger drive shall be provided with a clutch.
The progress in the work, the readings of the gauge pipes, the jacking pressures observed, etc.,
shall be recorded in a log book, to be shown to Company upon request. All information shall
be supplied to Company on completion of the work.
If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and plugged
at either end. The diameter of the casing pipe shall be as indicated in the job standards.
Company reserves the right to inspect certain lengths of pipes to assess damages, if any, to the
corrosion coating of the carrier pipe used for boring. Contractor shall weld additional lengths
of pipe and pull the required extra lengths for Company's inspection. If during inspection any
defects are noticed, Contractor, in consultation with Company, shall carry out the remedial
measures, as required.

4ol ei ifillENGINEERS CONSTRUCTION OF PIPELINES
0?ex latRegilif INDIA LIMITED CROSSING ROADS, RAIL ROADS & 6-71-0052 Rev. 3
0112R 2120,12 .4.710.4) (A Govt of Inda Undertakm)
4.5 While welding of the casing and vent/drain pipes, internal high or low is not allowed.
Welding of casing and vent/drain pipes need not be radiographed, however, only normal
visual checks shall be carried out. Before welding, the single length of pipe shall be inspected
in order to check that there is no out of roundness and dents. When such defects are noticed,
these must be completely removed before joining the pipes. If these defects cannot be
repaired, the defective section shall be cut out.
4.6 In the case of crossings where excavation has been authorised, the welding for the casing pipe
and for a continuous section of the pipeline corresponding to the expected length shall be
carried out in the proximity of the crossing. Casing must be laid immediately after the
trenching. Casing pipe must be laid with a single gradient in order to allow for an easy
insertion and, if necessary at a future date, to allow for the removal or replacement of the
pipeline, leaving the casing undisturbed. The direction of gradient shall be marked in the
crossing drawings for future reference.
4.7 The installation of assembly of vent pipe units as approved by Company shall be carried out
by direct insertion and welding to the ends of the casing pipe before introducing the carrier
pipe to avoid damage to insulators from welding heat. The operation of assembling and
extending the vent pipe shall be carried out in such a way that there is no contact with the
carrier pipe. The painting/coating of the vent pipes shall be applied before backfilling as per
relevant specifications.
4.8 The casing pipe shall be considered ready for installation of the carrier pipe, after careful
inspection and internal cleaning with the removal of soil, mud, stones and other foreign
materials.
4.9 Insulators, as approved by Company, shall be securely fastened to the pipe with all bolts and
fixtures firmly tightened. The number of insulators and spacing shall be as shown in the
drawings or at 2.5 meters center (whichever is more stringent). At the end of both sides of the
casing, a double set of insulators shall be installed.
4.10 Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is aligned
correctly in the casing and that the pushing or pulling force is evenly and constantly applied to
avoid damages to the insulators. A nose piece having a diameter equal to that of the pipe shall
be welded on the front and back end of the carrier pipe to facilitate installation of the carrier
pipe properly in the casing and to keep it dry and clean.
4.11 After installation of the carrier pipe section, the casing and the appurtenances, but prior to
making tie-in welds and backfilling, an electrical test shall be conducted by the Contractor in
the presence of the Company, to determine the resistance between the casing and the carrier
pipe or the carrier pipe and the soil. These tests shall show at least a resistance of 100,000 ohm
M2 . After backfilling and compaction, additional tests shall be conducted to determine if the
casing is electrically shorted to the pipe. If the installation is found to be shorted, Contractor
shall make the necessary corrections and repairs at his cost, unless a test to the satisfaction of
the Company is obtained.
4.12 After successful installation of crossing to the satisfaction of Company/Authorities having

jurisdiction, the nose pieces/pulling head welded to carrier pipe as an installation aid shall be
cut/removed and ends of carrier pipe shall be beveled/prepared for further welding/tie-in with
the balance section of pipeline on either side of crossing. Casing end-seals shall be
installed/fitted prior to back filling.

• MINERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
Mery PRIORMAPP.1) UMITED CROSSING ROADS, RAIL ROADS &
(A GOVI. of Ind. Undirtiking)
5.0 CROSSINGS OF BURIED SERVICES
5.1 The pipeline under construction may pass above or below the existing buried facilities such as
pipelines, cables, etc. Type of crossing shall be such that a minimum depth of cover as
required in the drawings and specifications are guaranteed. The clearance required between
pipeline and the existing facility shall be 500 mm (min)) as indicated in job standard.
5.2 Whenever buried services in the RoU are to be crossed by Contractor, Contractor shall
safeguard the buried facilities and the required protecting precautions shall be executed as
approved by Owners of the buried services and by Company.
5.3 For buried services to be crossed by boring/jacking, the relevant provisions of Section 4.0
shall apply.
6.0 MINOR WATER COURSE CROSSINGS
6.1 Minor water crossings are crossings of (future) ditches, canals, water courses, rivers, streams
etc., whether the bed(s) contain(s) water or not, and such crossings are not being specified as
"Major Water Crossings" in the CONTRACT.
6.2 For minor water crossings a standard drawing or a separate detailed approved drawing for
individual crossing shall be applicable, and all further specifications are applicable.
6.3 Whenever minor water crossings in the RoU are to be crossed, Contractor shall install bridges
and further comply with the provisions as laid down in this specification.
6.4 In crossings of water courses with either moderate flow rate or of torrential nature with
marked and unpredictable flooding, an adequate survey shall be carried out before starting the
work with the object of determining what precautions are necessary and the most favorable
period for executing the work.
6.5 In case of crossings of water courses for which no special methods of laying are required, a
pipe section of a size as per the approved drawings shall be assembled and subsequently laid.
Bends shall be of cold field type.
Whenever required by Company, Contractor shall, before start of construction, execute soil
investigations. Based on the soil investigations, the Contractor shall prepare a construction
drawing, work method and time schedule for approval by Company.
The depth of the existing bottom of a minor water course crossing shall be determined in
relation to the adjacent ground level by taking the average of four measurements.
Measurements shall be taken with a gauge rod and with dimensions 60x60 mm and having a
flat bottom. The minimum force to be exerted shall be 360N (36 kgf).
Contractor shall take special care to check with the responsible authorities for special
conditions applying to working on, over, under or thorough minor water crossings and
Contractor shall comply with any such conditions. Written arrangements with authorities shall
be drawn up in cooperation with Company.
6.6 The minimum cover over the pipe shall be as specified in the relevant approved drawings and
job standard.
6.7 For crossing beneath the bed of water courses, the pipe section shall be made in such a way
that it conforms to the existing or future bed as indicated in the approved drawings. In
crossings for which an individual drawing has not been prepared, the minimum cover of the

thENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
fat alegw INDIA
e1keer2 Marken)
LIMITED
IA Govt. Of India Undertaking)
CROSSING ROADS, RAIL ROADS &
pipeline shall not be less than that indicated in the standard drawings for a similar type of
crossing.
6.8 Whenever the crossing requires a straight section of pipe between the lower bends coinciding
with the river bed, this section shall be laid at a single horizontal level.
6.9 For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall be
prepared, laid and tested in accordance with the applicable clauses of Section 4.0 of this
specification.
6.10 The Contractor shall arrange temporary installation of diversions as may be necessary, to
ensure the effective functioning of these watercourses crossed, to the entire satisfaction of the
concerned local Authorities as well as the Company.
6.11 Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by Company and shall be thoroughly compacted to prevent soil and bank erosion as
per the drawings and standards to the satisfaction of authorities having jurisdiction thereof and
the Company. Whenever boulders, rock, gravel and other hard objects are encountered, they
shall not be placed directly on the pipe. Sufficient earth, sand or selected and approved
backfill material shall be backfilled initially around and over the pipe to provide a protective
padding or cushion extending to a minimum thickness of 300 mm around the pipe before
backfilling remainder of the trench with excavated or other material as per approved drawings
and standards.
After the trench has been backfilled and during the clean up works, the minor water crossing
shall be cleaned across the whole width of the ROU.
When specified in the CONTRACT, Contractor shall repair the ditch bank with materials to
be supplied by him as follows:
The excavation shall be backfilled with well compacted solid soil, followed by a
minimum 0 25 m thick layer of properly shaped boulders (75-150 mm) encased in a net
of galvanized iron wire of dia 3 mm spaced at a maximum distance of 50 mm to be laid
over the backfilled, compacted and graded banks.
The lengths of the above protection shall be equal to the bank excavation and damage
and extending 2 m on either side. The width of this protection on the slope shall be
determined by the following:
2 m plus the highest water level
Upto the bottom of the crossing or 20 m below the highest water level
whichever is smaller.
6.12 The crossing of any embankments shall be carried out strictly in accordance with approved
drawings.
No drilling work on embankments shall be permitted without prior written approval from the
competent Authorities.
6.13 When specified in the CONTRACT, the complete river crossing (minor) must be hydrotested
post-installation after the backfilling of the trench. The test procedure shall result in a hoop
stress in pipe corresponding to 90% SMYS of the pipe material. After temperature
stabilisation, pressure shall be retained in the pipeline for a minimum twenty four (24) hours

gh ENGINEERS CONSTRUCTION OF PIPELINES 6-71-0052 Rev. 3
WV, MOW =MINI) II43IA LIMITED
IA Govt of Incla Undid/icing)
CROSSING ROADS, RAIL ROADS &
and recorded by manothennograph. The hydrostatic testing shall be carried out in accordance
with approved procedures.

ZaikleieENGINEERS
A9,..,wia-mk„., um INDIA
tA
iTED
Go N ol Info 11'Aft *mg)
MAJOR WATER CROSSINGS
(CONVENTIONAL TRENCHING)
6-71-0053 Rev. 3
Page 1 of 13
er age 'hi til l Trrcw fefftirr

arti40
FOR

SPECIFICATION RK RK VM DM
SPECIFICATION MKM SK AS VJN
SPECIFICATION KKS RK VC AS
Standards Standards
No by by
Approved by

tlIfazi-elat ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
EitategW" INDIA LIMITED
col of India U.Jedaon9) Page 2 of 13
Abbreviations:

OISD Oil Industry Safety Directorate
PNGRB Petroleum and Natural Gas Regulatory Board
RoU Right of Use
US DOT United States Department Of Transportation
Convenor: Mr. Vinay Mittal
Members: Mr. Raj Kumar

Mr. M. S. Gunjiyal
Mr. Atul Chhatwal
Mr. G. K. lyer (HO Construction)

STANDARD SPECIFICATION FOR
aM-Zradia ENGINEERS
sig7 Evreolw INDIA LIMITED MAJOR WATER CROSSINGS
6-71-0053 Rev. 3
(A Gat a/ Inda Undertaking) (CONVENTIONAL TRENCHING) Page 3 of 13
CONTENTS
1.0 SCOPE 4
3.0 GENERAL 5
4.0 TRENCHING 7
5.0 CONTINUOUS CONCRETE COATING 9
6.0 HYDROSTATIC PRE-TESTING 9
7.0 INSTALLATION 9
8.0 BACKFILLING AND BANK PROTECTION 10
9.0 POST-INSTALLATION HYDROSTATIC TEST 12
10.0 POST-CONSTRUCTION SURVEY 12
11.0 FINAL CLEAN-UP 12

laiffrae? ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
INDIA LIMITED
Sigiar Nareg, IA Govt of Ina. Undertaking) (CONVENTIONAL TRENCHING) Page 4 of 13
1.0 SCOPE
1.1 This specification covers the minimum requirements for the various activities to be performed
by Contractor for the construction of pipeline major water crossings by conventional trenching
method. Provisions of this specification are applicable only for "Major Water Crossing"
specifically named as such in the CONTRACT.
1.3 Contractor shall, with due care and diligence, execute the work in compliance with all laws,
by-laws, ordinances, regulation etc., and provide all services and labour, inclusive of
supervision thereof, all materials, excluding the materials indicated as "Company Supplied
Materials" in the CONTRACT, equipment appliances or other things of whatsoever nature
required in or about the execution of the work, whether of a temporary of permanent nature.
1.4 Contractor shall take full responsibility for the suitability, stability and safety of all operations
and methods involved in the work.
1.5 Contractor shall be deemed to have inspected and examined the work area and its
surroundings and to have satisfied himself so far as practicable as to the form and nature
thereof, including sub-surface conditions, hydrological and climatic conditions, the extent and
nature of the work and materials necessary for the completion of the work, and the means of
access to the work area.
1.6 Contractor shall be deemed to have obtained all necessary information subject as above
mentioned as to risks, contingencies and all other circumstances, which may influence the
work.
1.7 Contractor shall, in connection with the work, provide and maintain at his own costs all lights,
guards, fencing, watching etc., when and where necessary or required by Company or by any
duly constituted Authority for the protection of the work and properties or for the safety and
the convenience of public and/or others.

and Other Liquids
ASME B 31.8 Gas Transmission and Distribution Piping systems.
API RP 1102 Recommended practice for Liquid Petroleum Pipelines

Crossing Railroads and Highways.
OISD 141 Design and construction requirements for cross-country

hydrocarbon pipelines
e) PNGRB Guidelines
0 Part 192, Title 49 - Transportation of Natural and other Gases by Pipe Line
g) Part 195 Transportation of liquids by Pipe Line


am-zie ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
sig7 EitYreg
, INDIA LIMITED
iA GoN of Ind l aunn i ng, (CONVENTIONAL TRENCHING) Page 5 of 13
h) EIL Standard Specifications:
6-71-0051 Standard Specification for Pipeline Construction (Onshore)
6-77-0006 - Welding Specification for Onshore Pipelines for

Transportation of Gas
6-77-0007 - Welding Specification for Onshore Pipelines for

7-71-0014 : Navigable Waterway Pipeline Crossing Warning Sign
2.2 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern. In case of conflict
between the requirements of this specification and that of the above referred codes, standards,
specifications and practices, the requirements of this specification shall govern.
the words 'Shall' and 'Must' are mandatory.
3.0 GENERAL
3.1 All works of the pipeline major water crossing shall be performed in accordance with the
approved construction drawings, procedure, and other applicable documents as per the
CONTRACT, good pipeline practices and as directed by Company.
3.2 Before start of the field construction, Contractor shall submit in triplicate to Company, for
approval, for each major water crossing, a complete report containing at least:
i) Installation method.
Proposed time schedule indicating start and finish dates and detailed break-up of time
period for all critical activities associated with the work.
Required work area along with layout and location.
Equipment to be used (including number and capacity of equipment).
Manpower deployment during construction.
vi Proposed sub-contractors and/or vendors along with their scope of work.
The description of the installation method as a minimum shall include the following:
Study of water currents in relation to the method of launching (on bottom and on
surface).
Calculations for stability of pipeline during launching and final test.
Buoyancy Studies.
Preparation of fabrication yard and launching areas alongwith proposed layouts.

tiliaZtdifft ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
5Iga taRes t, INDIA LIMITED
ig
el3eW og JeaM) iA al,,u Undett*Png) Page 6 of 13
Pipeline construction details (including hauling, stringing, welding, NDT, concrete

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

test, checking of winch/crane pulling capacity etc.
Pulling arrangement including launch way and anchoring and braking device.
k) Trench correction before launching.
1) Method of positioning and sinking/lowering of pipeline.
Method of rectification of damages to the pipeline/coating, during launching.
Method of backfilling, bank protection and survey.
Final test procedure after backfilling.
Safety system adopted during rope/winch capacity test and during construction
including launching.
(1) Communication system adopted during construction/testing/survey.
r) Abandonment and recovery procedures.
Company shall inform Contractor within 21 calendar days, if any objection against the
document and procedures described requires resubmission by Contractor.
Approval by Company of the methods used by Contractor shall in no way relieve Contractor
from the sole responsibility for safe and satisfactory installation of the crossing.
3.3 Contractor shall comply with all the conditions and requirements issued by Authorities having
jurisdiction in the area where the work is to be performed. Contractor shall, at his own
responsibility, obtain necessary permits from the Authorities having jurisdiction, for
performing its work.
If no public roads exist, Contractor shall arrange at his own for access to work areas at no
extra time and cost to Company.
3.4 Pre-construction Surveys
Prior to start of any work, Contractor shall carry out a survey of the major water crossings and
acquaint himself with site conditions and to collect any data regarding the water velocity and
the tidal variation in the flow pattern and shall verify the suitability of his equipment and the
method of construction.

Eadft ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
LO Eilite g
HIM elealW0111)
n INDIA LIMITED
IA Goo of Inda Undeag ing) (CONVENTIONAL TRENCHING) Page 7 of 13
4.0 TRENCHING
4.1 Dredging/Excavation
4.1.1 Contractor shall dredge or excavate the trench for the water crossing in conformity with the
approved drawings. Dredging of the trench shall be executed as accurately as possible.
4.1.2 The trench shall be excavated to such depth as required to provide the minimum cover and the
pipeline configuration as specified. The pipeline profile of the crossing shall be followed as
accurately as possible. Before laying, the trench shall be cleaned and leveled. The trench shall
be subject to inspection by Company prior to installation of the pipe.
4.1.3 Navigational traffic shall not be obstructed, unless permission has been given thereto.
Contractor shall issue all necessary publication according to the local requisitions.
Instructions given by Authorities shall be followed accurately and immediately, so that traffic
encounters no hindrance.
Contractor can not request a compensation if his work is hampered or delayed due to weather
conditions, any obstacles/or any traffic on the spot, where work is executed.
4.1.4 Contractor is fully responsible for the execution of the blasting (wherever permitted), the
dredging and excavation work, hopping of the spoil, transportation, dumping on land or in
water, all to be executed in agreement with Authorities, land owners and Company.
4.1.5 Contractor may be obliged to dredge or excavate a trench deeper or wider than indicated in the
drawings in order to properly lay the pipeline in unstable (underwater) areas, or near and
adjacent to the banks of water-courses. It shall be understood that Contractor is aware of such
problems at the time of his Bid and that, when such additional excavation is required, it shall
be done by Contractor as part of the work and that he will install the necessary provisions
and/or temporary works such as sheet-piling, special filling materials, etc. at no extra cost to
Company.
4.1.6 During the execution of dredging work by Contractor, bearings, measurements and levels shall
be taken by or on behalf of Company. Contractor shall render assistance for this purpose and
make available for Company appropriate survey boats, fully manned and equipped, before the
trench excavation work of the water crossing can be started. Contractor, if so desired by
Company, shall make cross profiles at intervals of not more than 10.0 m of the bottom of the
watercourse along the surveyed centerline of the water crossing. In such a case, horizontal
measurements shall be taken by triangulation or tapping between known points and shall be
made with such accuracy that the location of each vertical measurements is known with 1.0 m.
Vertical measurements shall be taken with a sonic recording device, or with line and rod, as
directed by Company and shall be taken with such an accuracy that each depth is known
within 0.2 m. Vertical measurements shall be taken at points averaging not more than 5.0 m
apart and no two measurements shall be more than 7.0 m apart. The cross profiles shall extend
at least 10 m on both sides of the top of the trench.
All measurements shall be recorded by Contractor. Company may witness such

measurements. The resulting profile, corrected to the elevation of the undisturbed watercourse,
shall then be the reference profile. Said profile shall be plotted on a 1:200 vertical and
horizontal scale.
4.1.7 Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be
made to the Company by reason of its caving either before or after the pipe is laid. Contractor
shall do whatever is required to excavate the trench, install the pipe in it and backfill the
trench in accordance with the specifications at no extra cost to Company.

5i1WeleTt"
i ENGINEERS
si
gar Weglilly INDIA LIMITED India undertak ing)
6-71-0053 Rev. 3
Page 8 of 13
4.1.8 Immediately before installation of the water crossing in the excavated trench, Contractor shall
prepare a profile of the trench bottom along the surveyed center line of the water crossing for
comparison with the reference profile. Contractor shall also make cross sections of the trench
at intervals of not more than 50 m. All profiles and cross section measurements shall be taken
as specified and, if required, shall be witnessed by Company. These data shall be submitted to
Company for approval and Company will approve or reject the trench excavation as
completed within 24 hours after receipt of the profile and cross sections.
4.1.9 Contractor shall grade the trench in such a manner as to give the maximum amount of uniform
support to the pipeline when it is lowered or pulled into place. The maximum unsupported
span shall not exceed 10.0 m.
4.1.10 In submerged sections, where rock or gravel is encountered in the bottom of the trench,
padding is required. The thickness of the padding under the concrete coated pipe shall at least
be 0.5 m and after installation at least 0.5 m around the pipe.
Blasting, if any, and padding shall be included in the Contractor's work.
4.2 Pumping Line
In case Contractor uses pumping lines to discharge the spoil, he shall take care of the
necessary permits.
Pumping lines, discharges and siphons shall be installed by Contractor and removed before the
completion of the work. At crossing with existing roads, the pumping lines shall be led
through a casing pipe bored/jacket under the road or led through a porch over the road. A
stress calculation must then be handed over to Company. The necessary provision to embank
the dumping area and also the spoil basins shall be made by Contractor. Contractor is
responsible for transportation of the spoil and dumping on land and is liable for damage to
works of third parties caused by leakage of pumping lines, etc. Contractor shall at all time
prevent overflow of pumping water, spoil or sand over embankments, parcels or roads. Further
more, Contractor shall safeguard Company from claims of compensation by third parties due
to encountered damage.
4.3 Spoil
Spoil which is not dumped on and including spoil acquired after cleaning the water crossing
trench, shall be transported and dumped in places, designated thereto by agreement between
Contractor and Authorities and approved by Company. Spoil shall be transported in (split),
barges; only those barges shall be used that avoid spilling during transportation due to
incorrect closing of the flaps, etc. Spoil, which is dumped outside the designated places shall
be removed by Contractor at first notice by Company.
4.4 Dikes, Dams and Weirs
Contractor shall install temporary provision in the existing dikes, dams, etc. to prevent
flooding of low areas.
Therefore in general, in existing dikes, dams, etc. a double substituting weir must be installed
before start of excavation in the existing dike or dam. Such a double substituting weir can be a
closed wall of sheet piling, supported by soil. The provisions shall be such that the underwater
profile of the dredged trench, the water movement caused by ships etc. cause no slides/cave-
ins of the dike or dam.

Oft& ofII ENGINEERS MAJOR WATER CROSSINGS
5itgar w INDIA LIMITED
,A00., on. (CONVENTIONAL TRENCHING)
6-71-0053 Rev. 3
Page 9 of 13
4.5 Pollution Control Measures
Contractor shall take all necessary precautions not to pollute river water and banks during
entire construction operation. Equipment deployed and construction methodology adopted
shall be such that minimum damage is caused to the existing environmental conditions. Union
and State Government requirements concerning pollution control and environmental
protection shall be fully complied with.
5.0 CONTINUOUS CONCRETE COATING
Contractor shall provide concrete coating over the pipeline including the bends in accordance
with the specification issued for the purpose and approved procedure. Contractor shall coat the
weld joints in order to arrive at the continuously concrete coated pipeline. However the
concrete coating shall be applied after the hydrostatic pretest.
6.0 HYDROSTATIC PRE-TESTING
Contractor shall hydrostatically pre-test the pipe string of each water crossing before
installation as per approved procedure.
Joint coating of the welds shall be done after this pre-test.
The section of the pipeline corresponding to the major water crossing shall, before installation,
be subjected to hydrostatic pretesting on a combined equivalent stress of 90% of the SMYS of
the pipe material. After the temperature has been stabilised, the pressure shall be maintained in
the pipeline for at least four hours and recorded by manothermograph. During test, the
Contractor shall check all welds for leakage. Failure, if any, during the test shall be rectified
by the Contractor. If the same is due to failure on account of any cause other than defect in
materials supplied by Company, the repairs shall be done free of cost, to the satisfaction of
Company.
7.0 INSTALLATION
7.1 Contractor shall submit a detailed scheme for the method he proposes to adopt for installing
the pipeline to Company for approval. Contractor shall calculate all stresses in the pipeline
while laying and check whether the stresses remain within permissible limits. A set of all
calculations shall be submitted to Company for approval.
7.2 Contractor shall perform all work required to install the water crossings, including the possible
appurtenances indicated in the drawings. The water crossings shall be installed in such a
manner as to comply with the requirements and conditions stated by the Authorities issuing
the permits. Contractor shall pay special attention to minimise any damage to embankments
and dikes in the vicinity of water crossings.
7.3 The equipment for launching shall be arranged in such a way that the pipeline is laid without
impact or jerking and is not subjected to stresses of any type other than those which are
allowable. Minimum allowed radius of curvature shall be followed, particularly at the end of
the launching way towards the water in the freely suspended section. During the launching the
pipe shall have a submerged weight of 30 kg/meter with a tolerance of ±10%.
7.4 After the water-crossing section has been installed in place, Contractor shall fill this pipeline
section including the pertaining land pipeline sections with water for the final testing.
7.5 Contractor shall check if the position and depth of the water crossing are in accordance with
the approved drawing, by means of a profile of the pipeline, before and after the water-
crossing section is filled with water. Contractor shall lower each pipeline section, which is not
sufficiently deep by dredging or jetting the underlying ground.
,d,,,th ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
lakitagW: INDIA LIMITED (CONVENTIONAL TRENCHING)
1.ff3n eT2Or2OnJO:FA) Govt ol loda U„Oetlacng, Page 10 of 13
7.6 The maximum allowed horizontal deviation from the required center-line shall be limited by
the following:
For pipeline dia up to including 500 mm 300 mm
For pipeline dia greater than 500 mm 500 mm
7.7 Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom contour of
the trench grade, so that it will be firmly, uniformly and continuously supported within the
permissible limits of unsupported spans as specified in Para 4.1.9. Company may employ a
diver or use other suitable methods to inspect the bottom of the trench and/or after the pipe is
installed prior to backfilling of the trench. Contractor shall facilitate the work of the diver and
shall furnish the necessary equipment and helpers necessary for the diver/inspector to perform
his work.
7.8 If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy the
minimum requirements of cover as specified in approved drawings, the Contractor shall make
necessary corrections to either trench or to the pipe alignment or to both so that the pipe, when
finally in position in the trench, shall fully meet the specification, failing which Contractor
may be asked to remove the pipeline. This shall be done at no extra time and cost to the
Company.
7.9 Installation of Parallel Pipelines
When parallel pipelines are required to be installed across major water crossing, Contractor
shall further comply with the following requirements.
7.9.1 Depending on the diameter of the parallel pipelines, the characteristics of the crossing and the
limitation of Contractor's equipment, Contractor may propose installation of the parallel
pipelines either together in a combined operation or separately in a common trench.
7.9.2 If the pipelines are installed together, the minimum clear distance between the parallel
pipelines (measured from the outside diameters of the concrete coated pipes) shall be 300 mm.
Contractor shall provide spacers (at sufficient intervals along the length of the pipe sections),
securely fixed to the pipes, or shall propose other suitable alternative methods, so as to ensure
that the stipulated minimum clear distance is maintained. The buoyancy of the combined
installation (pipes+spacers) shall be checked before installation. The spacers may be removed
before the trench is backfilled.
Contractor shall furnish detailed drawings/calculations for the pipe assembly, showing the
details of spacers/other arrangements for Company's approval before start of construction.
7.9.3 If the parallel pipelines are installed separately in a common trench, the minimum clear
distance between the parallel pipelines in the trench shall be 5000 mm. Contractor shall ensure
that this minimum spacing is maintained till the time the trench is backfilled.
7.10 Construction Equipment
All critical construction equipment deployed shall have a factor of safety of 2 (minimum) over
the calculated loads/capacities.
8.0 BACKFILLING AND BANK PROTECTION
8.1 Backfilling of the water-crossing section shall be performed as described in the following
clauses.

OWIEq ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
LII Effireg, INDIA LIMITED (CONVENTIONAL TRENCHING)
IA Got of India undensong) Page 11 of 13
8.1.1 The bottom of the water way shall be reinstated to its original level by backfilling the trench in
a manner and with suitable material and as prescribed and approved by the Authorities and
Company. In case material other than the original spoil is required, this shall be supplied and
applied by Contractor.
Wherever boulders, rock, gravel and other hard objects are encountered, they shall not be
placed directly on the pipe.
Sufficient earth, sand or selected and approved back fill material shall be backfilled initially
around and over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 0.5 m around the pipe before backfilling remainder of the trench with excavated
or other material.
Wherever required by Company, Contractor shall cover the nearly backfilled trench with a
layer of rock boulders to be approved by Company over a width equal to the width of
excavated trench with an extra of 5m on either side at no extra cost to Company.
8.1.2 Backfilling progress of the trench shall be checked continuously and a daily progress report
shall be made in three-fold and handed over to Company.
8.1.3 All embankments and/or dikes, bed and banks shall be reinstated to their original state and
levels, unless otherwise prescribed in the drawings or by the competent Authorities or
Company.
8.1.4 All remaining spoil-deposits shall be cleaned by Contractor to the satisfaction of Company.
8.2 Bank Protection
Trenches in banks of major water crossing shall be backfilled with soil approved by Company.
The fill at the banks shall be compacted firmly and reinforced with sacked earth, or excavated
material and well compacted by other means as directed by Company to the satisfaction of
Authorities having jurisdiction thereof. In areas where the backfilled soil is expected to be of
loose type, which is prone to flow, the trench shall be backfilled with crushed rock of size
approved by Company and pipe shall be provided with adequate padding of soil of a quantity
approved by Company. After the trench has been backfilled and during the clean up works the
water crossing shall be cleaned across the whole width of RoU.
Unless stipulated otherwise by the Authority or by Company, Contractor shall protect the
banks of the major water crossings by using gravel and boulders filled embankment mattresses
of galvanized iron wire to be laid over the backfilled, compacted and graded banks. In case
slope of the banks is 1:1 or more, bank protection shall be carried out using gabions. Bank
protection works shall be carried out by Contractor in accordance with the drawings included
in the CONTRACT. All materials required for such works shall be supplied by Contractor and
all works carried out in accordance with specifications, approved drawings, instructions of
Company and to the complete satisfaction of Authorities having jurisdiction at no extra cost to
Company.
The length of the above protection shall be equal to the bank excavation and damage and
further extending 10 m on either sides. The width of the restoration on the slope shall be
determined by the levels:
2m above Highest Water Level, and
5m below Low Water Level or 60m along the slope from Highest Water Level,
whichever is the smaller.

lalazieT,AS ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
5.1g?:LL lEgrag 411fi INDIA LIMITED
wen eviclWan3q17.11 IA GOA of Incha Unde ptak riM (CONVENTIONAL TRENCHING) Page 12 of 13
8.3 Before final hydrostatic testing, Contractor shall "prove" the Diameter of the pipeline by
passing a gauging pig through the pipeline. The gauging pig shall be capable of locating and
detecting defects permitted by governing code. Contractor shall supply and install all
temporary scraper launchers receivers and other equipment, piping materials and other
consumables for the purpose.
9.0 POST-INSTALLATION HYDROSTATIC TEST
The complete water crossing must be tested immediately after the approved backfilling of the
trench. The test procedure shall result in a hoop stress in pipe corresponding to 90% SMYS of
the pipe material. After temperature stabilisation, pressure shall be retained in the pipeline for
a minimum twentyfour (24) hours and recorded by manothermograph. The hydrostatic testing
shall be carried out in accordance with approved procedures.
10.0 POST-CONSTRUCTION SURVEY
After laying of the pipeline, Contractor shall carry out a post-construction survey jointly with
Company. Any defects brought to the notice of Contractor shall be promptly corrected by
Contractor at his own expense to the complete satisfaction of Company.
11.0 FINAL CLEAN-UP
After completion of construction, Contractor shall clear the site of all balance material and
debris. All balance pipe lengths, in case supplied by company, shall be returned to Company's
designated stock yard(s). Site shall be cleared to the complete satisfaction of Company and
Authorities having jurisdiction. All such works shall be done at no extra cost to Company.
12.0 DOCUMENTATION
12.1 In addition to the documents specified elsewhere in this specification, Contractor shall submit
to the Company six copies of leach of the following documents/records.
Complete record of pipes "taken-over" from Company, number of pipe lengths used,
and record of return of balance pipe length to Company's designated stock yard(s)
Copies of the permits obtained from Authorities having jurisdiction for the various
works.
Records of Non Destructive Testing of welds.
Clearance certificates from the land owners and Authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline RoU and work areas.
12.2 After completion of construction, Contractor shall prepare and furnish six sets of copies and
two sets of reproducible of As-Built drawings for the crossings.
As-Built drawings shall be as a minimum, include the following information:
True profile of the bed and banks of water crossing along the pipeline after backfilling
True profile of the pipeline as installed and depth of cover at top of pipe at 10 m
interval.
Location and angle of sag bends and over bends.
Cross section along the pipeline indicating nature and extent of backfill materials,
thickness of concrete coating to pipe etc.
Isdfazieft-, ENGINEERS MAJOR WATER CROSSINGS 6-71-0053 Rev. 3
$'1gzi1 &Meg W INDIA LIMITED
ZWaftemijeorm) IA Govl of India underlaiong) (CONVENTIONAL TRENCHING) Page 13 of 13
Method and extent of bank protection.

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Otilktzett ENGINEERS FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
zg-iartataiegve INDIA LIMITED
tA Gov/ of Ada UM.tiong) OF ONSHORE PIPELINES Page 1 of 20
IN 41440141 * W41 deb acted

cr farT4r
FOR
HYDROSTATIC TESTING OF
ONSHORE PIPELINES
elNP Vil‘v itntA".

3 11.04.12 REVISED & REISSUED AS STANDARD RSB SKJ VM DM
SPECIFICATION
2 31.07.06 REVISED & REISSUED AS STANDARD MKM DD AS VC
SPECIFICATION
1 15.10.98 REVISED & REISSUED AS STANDARD KKS RK VC AS
SPECIFICATION
Standards Standards
Rev. Convenor Chairman
Date Purpose by by
No
Approved by

00-a-eke-a,l ENGINEERS
1g7 efflegei INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
IA Gan 01 ■ncla Undenakingi OF ONSHORE PIPELINES Page 2 of 20
Abbreviations:

OISD Oil Industry Safety Directorate (of India)
SMYS Specified Minimum Yield Strength
Members : Mr S. K. Jain
Mr. Raj Kumar
Mr. M. S. Gunjiyal

ENGINEERS
INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
,
sag709-eg IA Govl of loam Undertaking], OF ONSHORE PIPELINES Page 3 of 20
CONTENTS
1.0 SCOPE 4
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS 4
3.0 GENERAL 4
4.0 HYDROSTATIC TEST PROCEDURE MANUAL 5
5.0 TEST DURATION AND PRESSURE 5
6.0 EQUIPMENT AND INSTRUMENTATION 6

7.0 PROCEDURES 8
8.0 ACCEPTANCE 11
9.0 TERMINATION 11
10.0 TEST REPORT 12

11.0 MEASUREMENTS 12
12.0 CALCULATIONS 14
13.0 PRECAUTIONS DURING THE TEST 15
14.0 PRESERVATION OF PIPELINE 15
FIGURES
FIG.1 WATER COMPRESSIBILITY FACTOR VS PRESSURE AND TEMPERATURE
TABLES
TABLE-1 DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR

AND THE STEEL THERMAL EXPANSION FACTOR
Copyright EIL — All rights reserved

lolfaelela
ENGINEERS
FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
GigalialitegW INDIA LIMIED OF ONSHORE PIPELINES Page 4 of 20
1.0 SCOPE
1.1 This specification covers the minimum requirements of supply, work and operation to be
performed by Contractor for hydrostatic testing of cross-country steel pipelines transporting
hydrocarbons in liquid or gaseous phase under high pressure.
This specification does not cover the requirements of caliper pigging, drying/
pre-commissioning of the tested pipelines.
documents included in the CONTRACT between Company and Contractor. Unless specified
specification.
2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS
of issue of enquiry) of the following codes, standards and specifications.
ASME B31.4 Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids.
ASME B 31.8 Gas Transmission and Distribution Piping Systems.
API RP 1110 Pressure Testing of Steel Pipelines for the
Transportation of Gas, Petroleum Gas, Hazardous
Liquids, Highly Volatile Liquids or Carbon Dioxide.
ASME Sec. VIII Div. 1 : Boiler and Pressure Vessel Code- Rules for
Construction of Pressure Vessels.
e) OISD STD 141 Design and Construction Requirements for Cross
Country Hydrocarbon Pipelines
Company Standard Specifications
6-71-0051 Standard Specification for Pipeline Construction

(Onshore)
6-77-0006 Welding Specification for Onshore Pipeline for
Transportation of Gas.
iii) 6-77-0007 Welding Specification for Onshore Pipelines for
2.2 In case of conflict between the requirements of this specification and that of the above
referred codes, standards, and specifications, the requirement of this specification shall
govern.
The words "Shall" and "Must" are mandatory.

The words "Should', "May" and "Will" are non-mandatory, advisory or
recommended.
3.0 GENERAL
3.1 Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall
be performed in accordance with approved Hydrostatic Test Diagrams clearly indicating the
number of test sections and minimum and maximum test pressures in each test sections. The
maximum length of each test section shall not exceed 50 km.
Format No. 8-00-0001-F1 Rev. 0 Copyright El L — All rights reserved

PIRITRTIIIA, ENGINEERS
iaOteg WV INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
OF ONSHORE PIPELINES Page 5 of 20
3.2 For pipeline sections which in Company's opinion, once installed would require an
inordinate amount of effort for repair in case of a leak, a provisional pre-test shall be
conducted. However, after installation, such pre-tested sections shall be tested again along
with the entire pipeline.
3.3 Hydrostatic test shall commence only after mechanical and civil works completion, i.e., all
welds have been accepted and the pipeline has been laid and backfilled. Hydrostatic test shall
include those sections which have been previously tested viz. Rail/road crossings, major
water crossings including test on banks and in place after installation, and scraper traps at the
terminals. Contractor shall perform all works required for hydrostatic testing after obtaining
prior written approval from the Company.
4.0 HYDROSTATIC TEST PROCEDURE MANUAL
Contractor shall prepare for Company's approval a hydrostatic test procedure manual. The
procedure shall strictly comply with the requirements of this specification and shall be
submitted to Company for approval well in advance. The procedure manual shall include all
temporary materials and equipment, but not be limited to the following items:
A diagram for the system to be tested, indicating all fittings, vents, valves,
temporary connection, relevant elevations and ratings. The diagram shall also
indicate injection locations and intake and discharge lines.
Estimated amount of test water, water source, including required concentration of

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

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

equipment and instruments (including spares), their location and set-up and
proposed system for observation and recording of data during the pressure test.
Procedure for detection and location of leaks.
Procedure for dewatering the pipeline section(s) after testing, including a complete
description of all proposed equipment and instruments (including spares), their
location and set-up, the type and sequence of pigs and the pig tracking system along
with the pig specification.
i) Forms for recording the test data.
5.0 TEST DURATION AND PRESSURE
5.1 The duration of hydrostatic test shall be minimum 24 hours after thermal stabilization.
5.2 Unless specified otherwise in the Contract, the hydrostatic test pressure shall be as follows:

laWleila ENGINEERS
51 F Eardu Mir INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

.Govt of India Undenakirg) OF ONSHORE PIPELINES Page 6 of 20
For pipeline handling hydrocarbon in gaseous phase:

1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 31.8.
1.5 times the design pressure for pipeline located in Class-3 and Class-4 locations as
per ASME B 31.8.
For pipeline handling hydrocarbon in liquid phase:

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

The Contractor shall furnish all necessary equipment for performing the work as stated in
cleaning, flushing, filling, stabilising, testing and dewatering procedures.
This shall include, but not be limited to the following equipment and instruments:
Pigs for cleaning, filling and gauging
Cleaning pigs with spring loaded steel wire brushes. For internally coated
pipes, the pigs shall be provided with nylon/polyurethane brushes.
Four cup batching pigs.
Gauging pigs fitted with gauge plate.
The Contractor shall provide a sufficient number of pigs, including spares.
Fill pumps:
The Contractor shall determine the type and number of fill pumps in order to
guarantee the following:
Differential Head : 20% greater than the maximum required

Flow Rate Minimum 400 m3/h; Maximum 1000 m3/h
If a single pump is used, a standby unit must be available.

Variable speed positive displacement pumps equipped with a stroke counter to
pressurize the pipeline. The pump shall be capable of exceeding the maximum test
pressure by at least 20 bar. Contractor shall also ensure availability of standby
pressurizing pump.
Two positive displacement meters to measure the volume of water used for filling
the line. These meters shall be provided with a calibration certificate not older than
three months.
e) Portable tanks of sufficient size to provide a continuous supply of water to the pump
during filling and pressurizing.
0 Bourdon pressure gauges of suitable pressure range and accuracy.
g) Dead weight testers with an accuracy of 0.01 bar measuring with least count of 0.05
bar provided with a calibration certificate not older than three months.

1512-a-eqit ENGINEERS
a-iar Weg WW: INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
IA Geri ol India undertaking) OF ONSHORE PIPELINES Page 7 of 20
Two 48 hours recording pressure gauges complete with pressure recording charts
and ink, duly tested with dead weight tester prior to use. These shall be installed at
the test head.
Two temperature recorders for fill water.
Thermocouples duly calibrated for measuring the pipe wall temperature
Two laboratory thermometers of range 0°C to 60°C and with accuracy of ±0.2° C
to be used in thermowells.
I) Means to measure the volume of water necessary to drop the line pressure by 0.5
bar (container on scales or graduated cylinder)
Injection facilities to inject additives into the test medium in the required
proportions.
Communication equipment suitable for a continuous connection between the

beginning and the end of the test section and with the inspection team along the line,
in accordance with the requirements of Local Authorities.
The temporary scraper traps shall be installed according to the test section fixed in
the test procedure manual. Proper piping and valve arrangements shall be available
to allow launching and receiving of each pig independently.
The test heads shall be sized in conformity with ASME specification Section VIII,
Division 2.
Thermocouples for measuring the temperature of the pipe wall and soil shall be
installed at the following locations:
One pair of thermocouples at about 500 m distance from the pumping

head.
One pair of thermocouples every 2500 m of the pipe. The spacing may be
increased to maximum 5000 m depending on the terrain and nature of sub
soil along the alignment of test section.
One pair of thermocouples at about 500 m distance from the terminal head.
Thermocouples shall be attached on the external surface of the pipe after removal of
external coating and shall be adequately protected by padding with minimum 500
mm soil. After successful testing, the thermocouples shall be removed and damaged
coating shall be repaired as per applicable coating repair procedure, approved by
Company. For soil temperature measurements, the thermocouple shall be buried at
pipe centerline depth at a distance of 500 mm from the pipe wall.
q) Digital pressure/ temperature monitoring and chart recording systems can be used in
lieu of the components listed above provided that the individual pressure/
temperature sensors included in the system have a level of accuracy and can be field
calibrated in a manner similar to those instruments listed above. Instruments shall be
portable and rugged in construction with minimum weatherproof rating of IP-66.
They shall display pressure and temperature readings on the screen and shall have
adequate memory for recording the same. The instrument shall have computer
interface to export the stored data after completion of test.

011taae?0,11 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
a
^fs laWlegW;INDIA LIMITED
Undertaking)
In Gm/ of Inda
FOR HYDROSTATIC TESTING
OF ONSHORE PIPELINES
6-71-0055 Rev. 3
Page 8 of 20
7.0 PROCEDURES
7.1 Equipment and/or parts which need not or must not be subjected to the test pressures or
which must not be tested with water, must be disconnected or separated from the pipeline to
be tested.
7.2 If the difference of minimum and maximum atmospheric temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps and
above ground pipeline shall be properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric conditions, viz.
aerial lengths on piers, suspension bridges, etc. Such sections shall be tested separately.
7.3 The test medium shall be soft non-aggressive water furnished by the Contractor. The water to
be used shall be filtered, shall not be contaminated and shall be free from sand or silt.
Contractor shall submit laboratory test reports of water used for testing. The possible use of
sea water shall be subject to its degree of cleanness, the possibility of obtaining a pre-
determined salinity neutralisation and the use of corrosion inhibitors, this at the sole
discretion of Company. Contractor shall provide Company approved corrosion inhibitors,
oxygen scavengers and bactericides to be added to the test water. The Contractor shall
furnish and install all temporary piping, which may be necessary to connect from source of
water to its pump and manifolds/tankages.
The following products are acceptable for corrosion inhibition of the water used for hydro
testing:
REMIDOL 4000 of M/s Chemtreat India Ltd., Navi Mumbai.

HIBITOL 2000 of M/s Renkal Chemical, Navi Mumbai.
INDION 175 of M/s Ion Exchange India Ltd., Hyderabad.
VISCO 3900 of M/s NALCO EXXON.
Indicative dosage for inhibitor is as follows:
Upto 6 months 500 mg/I

Above 6 months 750 mg/I
However the exact dosage rates shall be as per the hydro test water analysis and manufacturer
recommendation.
Contractor shall note the following:
All chemicals for hydrotesting shall be procured from approved vendors. Chemicals
older than three months shall not be used.
Company representative shall inspect the chemical containers and take random
samples prior to its use. Contractor shall get the samples tested in an EIL nominated
Govt./PSU/other competent laboratories. Testing shall be carried out for accelerated
% corrosion inhibition efficiency, % SRB and TBC killing efficiency test. Company
reserves the right to witness the testing. The test report shall be submitted to Company
for approval prior to undertaking hydro testing works.
Only those chemicals which have passed the above tests shall be used for
hydrotesting.
Chemicals shall be injected by dosing pump only and mixing in open tank shall not be
al lowed
7.4 Before filling operation, the Contractor shall clean the pipeline by air driven pigs provided
with spring loaded brushes and chisels to remove all mill scale, rust, sand, etc. from the

ONZIE5/01SENGINEERS
s'gff EtfiregS INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
Govt of India Umiertaung) OF ONSHORE PIPELINES Page 9 of 20
inside of pipe section. For this purpose, temporary headers for air cleaning shall be attached
to the pipeline. The number of pig runs depends upon the cleaning results and shall be
determined by the Company at site.
7.5 After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried
out by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter
of the heaviest wall pipe in the test section. While computing the ID of heaviest wall pipe,
pipe manufacturing tolerances shall not be considered. A 10 mm thick aluminium plate shall
be used for making the gauge plate.
After receipt of gauging pig at the other end, the gauge plate shall be inspected in the
presence of Company representative. A deformed, bent or severally nicked plate or damaged
pig shall be evidence of gauging pig run failure and the same shall not be acceptable to
COMPANY. In such cases the Contractor shall repair and rectify the line and repeat the
gauging pig run to the satisfaction and approval of the Company Representative. Any
obstruction and/or faults such as dents, buckles, flat spots, etc. analysed and noted during
gauging pig run shall be located and any necessary repair work shall be performed to rectify
the same to the satisfaction of the Company. A written approval shall be obtained from
Company regarding successful completion of gauging pig run.
After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pigs shall be welded to test section.
The drawing of the test headers shall be submitted along with hydrotest procedure for
approval. All fittings and flanges to be used in the test header fabrication shall be at least one
ANSI rating higher than the line rating. The headers shall be pretested at line hydrotest
pressure for duration of minimum 24 hours. The record shall be kept and shall be part of the
final hydro test report.
Weld joints between test header and pipeline shall be radiographed. Un-inhibited water equal
to 10% of the volume of test section shall be introduced in front of the first pig. The first pig
shall be launched by introducing about 1.5 km un-inhibited water. Then the second pig shall
be launched by pumping the inhibited water till the second pig is received at the other end.
Subsequent to receipt of second pig, the pressurization and thermal stabilization operation
can commence.
7.6 Thermal stabilization
After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, the thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked through the
thermocouples installed on the pipeline and in the soil.
Pipe and soil temperature readings shall be taken at 2 hours-intervals. Thermal stabilization
shall be considered to have been achieved when a difference not higher than 1°C is attained
between the average pipe temperature and average soil temperature. Thermal stabilization
completion shall be approved by Company.
7.7 Pressurisation
7.7.1 The pressurization shall be performed in the presence of Company at a moderate and constant
rate not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel
with the dead weight tester. Volume required to reach the test pressure shall be recorded
periodically throughout the pressurization as follows:

Ii5ilatre?eft ENCJNEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
5g-9 ielffleg we INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
poll of India undertaking) OF ONSHORE PIPELINES Page 10 of 20
Each 5 bar increments up to 80% of test pressure as recorded by the dead weight
tester;
Each 2 bar increments between 80% to 90% of test pressure as recorded by the dead
weight tester;
c) Each 0.5 bar increments between 90% of the test pressure to full test pressure as
recorded by the dead weight tester.
7.7.2 The pressurisation shall be cycled according to the following sequence:
Pressurise to 50% of test pressure, hold pressure for 1 hour,

Drop pressure to static head of test section at test head,
Pressurise to 75% of test pressure, hold pressure for 1 hour
Drop pressure to static head of test section at the test head
e) Pressurise to test pressure.
During the pressurisation to each test pressure, two tests shall be carried out for the
calculation of air volume in the pipeline under test at 50% and 75% of test pressure.
In case, during the hold pressure periods indicated above, a decrease in pressure in observed,
the above operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the Contractor has isolated and eliminated the cause for the
lack of water tightness.
7.8 Air Volume Calculation.
In order to check the presence of air in the pipeline, two separate consecutive pressure
lowering of 0.5 bar shall be carried out after pressurizing to test pressure.
For calculation of air in the pipeline the second pressure lowering shall be used, and the
relevant drained water shall be accurately measured (V 1 ). This amount measured shall be
compared to the theoretical amount (Vp) corresponding to the pressure lowering that has been
carried out, by using the procedure outlined in clause 12.1 of this specification.
If no air is present in the length under test:
Vt —
1
VP
In order that the above ratio is acceptable, it shall not differ from I by more than 6% (i.e.
1.06). If the air found in the pipeline is within the above established tolerance, then the
pressurising can continue. If the ratio V I Np exceeds 1.06, the hydrostatic testing cannot go
on and additional pig passages shall be performed to remove the air pockets. V i Np ratio less
than 1 shall not be acceptable. In such a case all hydrotest calculations for Vp including pipe
book lengths shall be rechecked.
The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurising can then continue, to reach the value of the test pressure.
7.9 Testing
After the section has been pressurised and the air volume test has given acceptable results the
test pressure shall be held for a minimum of 24 hours after stabilisation. After temperature
and pressure has stabilished, the injection pump shall be disconnected and all connections at
the test heads shall be checked for leakage. The pressure recorders shall then be started with
the charts in a real time orientation for continuous recording throughout the test.

lairaeleis ENGINEERS
$j1g211 1 INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

During the testing period the following measurements shall be recorded/reported
Every one hour pressure measurements from dead weight testers.

Every two hour the ambient temperature and the pipe temperature at the
thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded. Bleed-off
water shall be accurately measured and recorded.
8.0 ACCEPTANCE
8.1 The hydrostatic test shall be considered as positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such changes shall
be evaluated as described under clause 12.2 of this specification.
The pressure change value as a function of temperature change shall be algebraically added
to the pressure value as read on the meters. The pressure value thus adjusted shall be
compared with the initial value and the test shall be considered as acceptable if the difference
is less than or equal to 0.3 bar. Incase of doubt the testing period shall be extended by 24
hours.
8.2 If test section fails to maintain the specified test pressure after isolation, Contractor shall
determine the location of leakage or failure by suitable means. All leaks and failures within
the pipe wall or weld seams shall be repaired by replacement of entire joint or joints in which
leakage or failure occurs. In those cases where leaks occur in circumferential welds the
method of repair shall be determined by the Company. Contractor shall comply with
instructions of the Company whether to replace a section of the line pipe that includes the
line leak or whether to repair the circumferential weld. This repair should, however, meet the
requirements of applicable welding specification enclosed with the Contract. Where failures
occur in pipeline field bends, bends shall be replaced with same degree of bends. After
completion of repairs, the hydrostatic test shall be repeated in full, as per this specification.
8.3 The cost of repairs or replacements, followed by refilling and repressurising the line, due to
poor workmanship, shall be borne by the Contractor. In the event of leaks or failures
resulting from faulty Company furnished materials, Contractor shall be reimbursed as per the
provisions of Contract. All work of reinstalling line pipe, to replace failures, shall be done in
accordance with the relevant specifications included in the CONTRACT.
8.4 Contractor shall haul and stockpile all damaged and defective pipes to storage location
designated by the Company. All cracks and splits resulting from failure shall be coated with
an application of grease to preserve the characteristics of failures from corrosion. Joint of
failed pipes shall be marked with paint, with a tag indicating failure details, date and location
of failure and pressure at which failure occurred. Failed pipes shall have pipe number and
heat number clearly marked on the outside surface along with warning sign to prevent re-
usage.
9.0 TERMINATION
After the positive result of testing and completion of data gathering, the test shall be
terminated upon written approval given by the Company. The pipeline shall be slowly
depressurised at a moderate and constant rate as instructed by Company. Subsequent
operations such as caliper pigging, swabbing, drying, purging/inertising and commissioning
shall be carried out as per the applicable specifications enclosed with the Contract.
9.1 Contractor shall dewater the tested line as per the following requirement after test acceptance.

araae? ENGINEERS
0g7 a are G., INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
IA God of India undertaking) OF ONSHORE PIPELINES Page 12 of 20
Dewatering shall be carried out by using four cup pigs and foam pigs driven by compressed
air. The detailed dewatering procedure shall be deployed by the Contractor in such a way as
to provide adequate control of pigs during dewatering. Pigs and equipment required for
dewatering the line shall be furnished by Contractor and shall be approved in advance by the
Company. Four cup pigs shall first be passed through the line to displace the water. Foam
pigs shall then be passed in order to complete the line dewatering. Contractor shall use a
number of foam pigs each in different colours/numbered for this purpose. The line shall be
considered dewatered when a negligible amount of water is flushed out by the last foam pig
and approval is given by the Company.
9.2 Before the start of dewatering and disposal of hydrotest water, a procedure for treatment of
inhibited water to prevent pollution shall be submitted by Contractor to Company for review
and approval. During dewatering, care shall be taken to properly dispose off the discharged
water in order to avoid pollution, damages to fields under cultivation and/or existing
structures and interference with traffic.
9.3 Upon completion of the testing and dewatering operation, any provisional traps for pigs and
all other temporary installation relating to the test shall be removed. Subsequently, the
individual sections of the line already tested shall be joined in accordance with the
requirements of relevant specifications issued for the purpose.
10.0 TEST REPORT
A complete report signed by Contractor and the Company shall be submitted upon
completion of the hydrostatic test for each test section.
This report shall contain as a minimum:
The cleaning, flushing, filling and testing procedures used;

Schematic layout of cleaning, filling and testing facilities;
Instrument calibration certificates;
A profile of the pipeline that shows the test sites, all instrument and injection
connections;
Pipe filling logs and records;
Additive specification, required concentration and additive injection records;
Pig specifications;
Pig inspection records including photographs of the damages;
Records of gauging pig survey and photographs;
Pressurisation and stabilisation records;
Pressure and temperature recording charts with appropriate information inscribed
thereon;
Temperature data along the pipeline;
Dead weight tester logs and recordings;
Air volume calculations;
Pressure change due to temperature change calculations;
Environmental data;
Depressurisation logs and records;
Dewatering procedure and schematic layout of relevant facilities;
Dewatering logs and records;
Records and photographs of all leaks, if applicable.
11.0 MEASUREMENTS
11.1 Water Amount Measurements

5110-Q3d ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
sgar lafReu VW INDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

("""e'"'"?`"anu
A Gent on inow unaenakingi OF ONSHORE PIPELINES Page 13 of 20
The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used).
In the calculation, as per clause 12.1 of this specification, use shall be made of the
geometrical volume of the section in question. The water amount that has been let into the
section shall be measured during the pressurisation stages thorough positive displacement
meters or turbine meters.
11.2 Pressure Measurement
Pressure shall be measured with a dead weight tester that shall permit readings with least
count of 0.05 bar.
During the test, the pressure shall be recorded by means of a recording pressure gauge
featuring the following specifications:
Accuracy ± 0.1% of the full-scale value

Recording Continuous on tape or disk, graph width 100mm
Feed 20mm/h for tape diagrams, 15°/h for disk diagrams
Recording range To be such as to record pressure between 50% and 90% of
the diagram width.
The recording pressure gauge shall be checked by means of dead weight test at the beginning,
and at the end of the hydrostatic test.
11.3 Temperature Measurements
Water temperature shall be taken at every 2 hours through the thermocouples that
have been installed on the pipe wall along the section under test.
Further, the temperature measurement shall be taken:
During the filling operation

During the thermal stabilisation stage
During the hydrostatic test
The thermocouples' sensitivity shall enable temperature readings with the accuracy
of ±0.1°C.
Water temperature shall also be measured on the pump delivery by means of a

recording thermometer throughout the filling stage.
The recording thermometer shall feature the following characteristics:
Accuracy : ± 1% of the scale range

Scale -10° to +40°C
Recording : Continuous on tape or disk, diagram width 100mm
Feed 20mm/h for tape diagrams, 15°/h for disk diagram
Ground temperature shall be taken at every two hours though the thermocouples
that have been installed in the soil along the section under test.
Environmental temperature shall be recorded from the beginning of pressurization

to the end of the test by means of a recording thermometer featuring the following
characteristics:

•-
OOZE? ENGINEERS
I mac'gINDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

IA Govt of India Undertaingj
Accuracy ± 1% of the scale range

Scale 0° to +60°C
Recording : Continuous on tape or disk, diagram width 100mm
Feed 20mm/h for tape diagrams, 15°/h for disk diagrams.
12.0 CALCULATIONS
12.1 The theoretical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall be calculated
by means of the following formula:
VP = (0.884 + +A) x 10-6 x Vt x AP xK
Where
Vp = computed water amount required to raise the pressure by AP in the section

to be tested (m3)
V, = geometrical volume of the section (m3)
AP = pressure rise (bar)
ri = nominal inner radius of the pipe (mm)
t = nominal pipe thickness (mm)
A = isothermal compressibility value of water at the pressurization temperature
in the P range (bar 1 ) x 106
(Refer water compressibility factor v/s pressure and temperature charts-
Figured , For temperature above 30°C the values may be extrapolated.)
K = a dimensionless coefficient that is equal to a value of 1.02 for welded
pipes.
12.2 The pressure change due to a water temperature change shall be calculated through the
following formula:
B
AP = AT
ri
0.884 +A
where
AP pressure change resulting from a temperature change (bar)

AT algebrical difference between water temperature at the beginning of the
test and water temperature as measured at the end of the test (°C).
Value of the difference between the thermal expansion of water at the
pressure and temperature as measured at the end of the test and that of steel
(°C- ') x 106
(Refer Table 1)
A Isothermal compressibility value of water as estimated at the pressure and
temperature values obtained at the end of test (ban x 106
(Refer Figure 1)
ri nominal inner radius of the pipe (mm)
(in case of the test section having multiple wall thicknesses, "ri" shall
correspond to the wall thicknesses, having the maximum total length in the
given test section).
nominal pipe thickness (mm)

101 1at5a ENGINEF_RS
LII tafWIegli_V INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3
CA Govl of India Undeitaikap/ OF ONSHORE PIPELINES Page 15 of 20
13.0 PRECAUTIONS DURING THE TEST
In addition to all that has been expressly described in the procedures for carrying out the
tests, the following additional requirements shall be complied with:
13.1 Provision shall be made for the installation of no-admittance signs to unauthorised personnel
from the roads to the R.O.U.
13.2 Signs stating 'PIPE UNDER TEST-KEEP OFF" with local language translation shall be
placed where the pipeline is uncovered, and particularly where the provisional traps and
stations are located. Such areas shall be suitably fenced in such a way as to prevent access of
unauthorised personnel. No unauthorised personnel shall be closer than 40M to the pipeline
or equipment under test.
13.3 Provisional scraper traps shall be installed in compliance with methods and suitable location
so that their rupture cannot cause any injuries to the personnel or third parties.
13.4 The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.
13.5 Once dewatering is over the sectionalising valves and other valve assemblies tested
previously, shall be installed at locations shown in the drawings and in accordance with the
procedures contained in the relevant specifications. All thermocouples installed in the
pipeline shall be removed and damaged corrosion coating shall be repaired using Company
approved materials and procedure.
14.0 PRESERVATION OF PIPELINE
When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified

duration, Contractor shall completely fill the pipeline with water, with sufficient quantity of
corrosion inhibitors depending upon quality of water and the period of conservation, at a
pressure to be agreed upon with the Company at a later stage. Contractor shall obtain
necessary approval from the Company of the procedure, type and quality and quantity of
inhibitors used before commencement of the works.

laraaeqeS ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ElPegWINDIA UMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

IA Gm/ Mirada Undertaking; OF ONSHORE PIPELINES Page 16 of 20
50
49
48
47
46
45
44
43
18
20
22
42 24
26
20
30
41
40
40 80 120 160 200 240 280 300
PRESSURE (BAR g)
FIG 1. WATER COMPRESSIBILITY FACTOR v/s. PRESSURE AND TEMPERATURE

Oti=dire? FOR HYDROSTATIC TESTING
INDIA LIMITED 6-71-0055 Rev. 3
51129-e , IA Go v% at India Underwent') OF ONSHORE PIPELINES Page 17 of 20
°C 2 3 4 5 6 7 8
1
bar
.981 -98.62 -79.89 -61.81 -44.34 -27.47 -11.14 +4.66 +19.98
10 -95.55 -76.94 -58.99 -41.65 -24.89 -8.67 +7.02 +22.23
20 -92.15 -73.68 -55.86 -38.64 -22.01 -5.92 +9.65 +24.74
30 -88.74 -70.40 -52.72 -35.63 -19.14 -3.16 +12.29 +27.26
40 -85.32 -67.12 -49.58 -32.62 -16.24 -0.41 +14.93 +29.78
50 -81.90 -63.84 -46.43 -29.60 -13.36 +2.36 +17.57 +32.31
60 -78.47 -60.55 -43.27 -26.58 -10.46 +5.15 +20.23 +34.85
70 -75.03 -57.25 -40.10 -23.54 -7.56 +7.92 +22.89 +37.89
80 -71.60 -53.96 -36.94 -20.51 -4.65 +10.70 +25.55 +39.94
90 -68.16 -50.66 -33.77 -17.47 -1.73 +13.50 +28.23 +42.50
100 -64.72 -47.35 -30.60 -14.43 +1.18 +16.29 +30.90 +45.05
110 -61.28 -44.05 -27.43 -11.38 +4.10 +19.08 +33.58 +47.67
120 -57.84 -40.74 -24.26 -8.34 +7.02 +21.88 +36.26 +50.18
130 -54.40 -37.44 -21.08 -5.29 +9.95 +24.68 +38.94 +52.75
140 -50.96 -34.13 -17.90 -2.25 +12.87 +27.49 +41.63 +55.32
150 -47.53 -30.83 -14.73 +0.80 +15.79 +30.29 +44.31 +57.89
160 -44.10 -27.53 -11.56 +3.85 +18.72 +33.10 +47.00 +60.46
170 -40.67 -24.23 -8.40 +6.89 +21.64 +35.90 +49.69 +63.04
180 -37.24 -20.94 -5.23 +9.94 +24.56 +38.70 +52.37 +65.62
190 -33.83 -17.65 -2.06 +12.98 +27.48 +41.51 +55.06 +68.19
200 -30.42 -14.37 +1.09 +16.01 +30.40 +44.30 +57.75 +70.77
210 -27.02 -11.09 +4.25 +19.04 +33.31 +47.10 +60.43 +73.34
220 -23.63 -7.82 +7.40 +22.06 +36.22 +49.90 +63.12 +75.90
230 -20.24 -4.56 +10.54 +25.08 +39.13 +52.69 +65.80 +78.48
240 -16.87 -1.30 +13.67 +28.10 +42.03 +55.48 +68.48 +81.05
250 -13.50 +1.94 +16.79 +31.11 +44.92 +58.26 +71.15 +83.61
260 -10.14 +5.17 +19.90 +34.12 +47.81 +61.04 +73.81 +86.81
270 -6.80 +8.39 +23.00 +37.11 +50.69 +63.80 +76.48 +88.73
280 -3.48 +11.60 +26.11 +40.09 +53.56 +66.57 +79.14 +91.29
290 -0.17 +14.80 +29.19 +43.07 +56.43 +69.33 +81.78 +93.83
300 +3.13 +17.98 +32.27 +46.03 +59.29 +72.08 +84.83 +96.38
Table 1 : Difference between the water thermal expansion factor and the steel thermal expansion
FACTOR (°C-1) 10-6

SSW"leia ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
laPege NIP INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

+NTT ereaweauw R) Gort of Indla Uncleftalcingl OF ONSHORE PIPELINES Page 18 of 20
°C 10 11 12 13 14 15
9
bar
.981 +34.82 +49.22 +63.20 +76.78 +89.99 +102.83 +115.34
10 +36.97 +51.26 +65.15 +78.64 +91.75 +104.51 +116.93
20 +39.36 +53.55 +67.33 +80.71 +93.72 +106.39 +118.71
30 +41.76 +55.84 +69.51 +82.79 +95.70 +108.26 +120.49
40 +44.18 +58.14 +71.70 +84.87 +97.68 +110.14 +122.28
50 +46.60 +60.45 +73.90 +86.96 +99.68 +112.04 +124.07
60 +49.02 +62.76 +76.10 +89.07 +102.67 +113.93 +125.88
70 +51.44 +65.08 +78.32 +91.17 +103.68 +115.84 +127.69
80 +53.88 +67.40 +80.53 +93.29 +105.69 +117.76 +129.50
90 +56.32 +69.73 +82.75 +95.41 +107.70 +119.67 +131.32
100 +58.77 +72.07 +84.98 +97.53 +109.73 +121.59 +1333.15
110 +61.21 +74.41 +87.22 +99.66 +111.75 +123.52 +134.98
120 +63.67 +76.74 +89.45 +101.79 +113.79 +125.46 +136.82
130 +66.12 +79.09 +91.69 +103.93 +115.83 +127.39 +138.67
140 +68.58 +81.45 +93.93 +106.07 +117.87 +129.34 +140.51
150 +71.05 +83.80 +96.18 +108.21 +119.90 +131.20 +142.37
160 +73.51 +86.15 +98.43 +110.36 +121.96 +133.74 +144.22
170 +75.97 +88.51 +100.68 +112.51 +124.01 +135.19 +146.08
180 +78.44 +90.87 +102.94 +114.66 +126.06 +137.15 +147.94
190 +80.91 +93.23 +105.19 +116.82 +128.12 +139.11 +149.81
200 +83.37 +95.59 +107.45 +118.97 +130.17 +141.07 +151.68
210 +85.84 +97.95 +109.71 +121.13 +132.24 +143.03 +153.55
220 +88.30 +100.31 +111.97 +123.29 +134.29 +144.99 +155.42
230 +90.67 +102.67 +114.23 +125.45 +136.36 +146.96 +157.30
240 +93.22 +105.03 +116.48 +127.60 +138.42 +148.93 +159.18
250 +95.69 +107.39 +118.74 129.76 +140.48 +150.90 +167.05
260 +98.14 +109.74 +121.00 +131.92 +142.54 +152.87 +162.93
270 +100.60 +112.10 +123.25 +134.08 +144.61 +154.84 +164.81
280 +103.05 +114.44 +125.50 +136.24 +146.67 +156.84 +166.69
290 +105.50 +116.79 +127.75 +138.39 +148.73 +158.78 +168.57
300 +107.94 +119.13 +130.00 +140.54 +150.79 +160.75 +170.45
FACTOR (°C 1) 10-6

a EVregVif INDIA LIMITED

151fazie?
wart eiewMIJC15.11
ENGINEERS
IA GoN 01 India undetiakingJ
FOR HYDROSTATIC TESTING
OF ONSHORE PIPELINES
6-71-0055 Rev. 3
Page 19 of 20
°C 19 20 21 22 23
16 17 18
bar
.981 +127.52 +139.41 +151.00 +162.31 +173.37 +184.18 +194.75 +205.08
10 +129.02 +140.83 +152.36 +163.58 +174.56 +185.30 +195.79 +206.07
20 +130.71 +142.42 +153.85 +165.00 +175.90 +186.55 +196.96 +207.16
30 +132.40 +144.02 +155.35 +166.42 +177.23 +187.80 +198.14 +208.26
40 +134.10 +145.62 +156.87 +167.85 +178.58 +189.07 +199.33 +209.37
50 +135.80 +147.24 +158.39 +169.29 +179.93 +190.34 +200.52 +210.49
60 +137.51 +148.86 +159.92 +170.73 +181.29 +191.62 +201.72 +211.61
70 +139.22 +150.49 +161.46 +172.18 +182.66 +192.91 +202.93 +212.74
80 +140.95 +152.11 +163.00 +173.64 +184.03 +194.20 +204.14 +213.88
90 +142.67 +153.75 +164.56 +175.10 +185.41 +195.50 +205.36 +215.03
100 +144.42 +155.40 +166.11 +176.58 +186.80 +196.80 +206.59 +216.17
110 +146.15 +157.04 +167.66 +178.05 +188.20 +198.12 +207.82 +217.33
120 +147.90 +158.70 +169.24 +179.54 +189.59 +199.44 +209.06 +218.49
130 +149.65 +160.36 +170.81 +181.02 +191.00 +200.75 +210.31 +219.66
140 +151.40 +162.03 +172.39 +182.51 +192.41 +202.09 +211.56 +220.84
150 +153.16 +163.70 +173.98 +184.00 +193.82 +203.42 +212.81 +222.02
160 +154.93 +165.37 +175.56 +185.51 +195.24 +204.76 +214.08 +223.20
170 +156.69 +167.05 +177.15 +187.02 +196.66 +206.10 +215.34 +224.39
180 +158.47 +168.73 +178.75 +188.53 +198.09 +207.45 +216.61 +225.58
190 +160.24 +170.42 +180.35 +191.05 +199.52 +208.80 +217.89 +226.79
200 +162.01 +172.10 +181.95 +191.57 +200.97 +210.16 +219.17 +227.99
210 +163.80 +173.80 +183.55 +193.09 +202.40 +211.53 +220.46 +229.20
220 +165.58 +175.49 +185.16 +194.62 +203.85 +212.89 +221.74 +230.41
230 +167.36 +177.19 +186.78 +196.14 +205.30 +214.26 +223.04 +231.63
240 +169.16 +178.89 +188.39 +197.68 +206.75 +215.63 +224.32 +232.85
250 +170.94 +180.59 +190.01 +199.21 +208.20 +217.00 +225.63 +234.08
260 +172.73 +182.30 +191.63 +200.75 +209.66 +218.40 +226.93 +235.31
270 +174.53 +184.00 +193.25 +202.29 +211.12 +219.77 +228.24 +236.54
280 +176.32 +185.70 +194.88 +203.83 +212.59 +221.16 +229.55 +237.77
290 +178.11 +187.42 +196.50 +205.37 +214.05 +222.54 +230.86 +239.01
300 +179.90 +189.13 +198.13 +206.92 +215.51 +223.93 +232.18 +240.26
FACTOR (°C') 10-6

aMzre? eh ENGINEERS
it le151-ctW , INDIA LIMITED FOR HYDROSTATIC TESTING 6-71-0055 Rev. 3

ewt,„,..„„nu undenaung)
IA Govt on India OF ONSHORE PIPELINES Page 20 of 20
°C 26 27 28 29 30
24 25
bar
.981 +215.22 +215.14 +234.88 +244.41 +253.79 +263.00 +272.03
10 +216.13 +225.99 +235.66 +245.13 +254.44 +263.59 +272.57
20 +217.15 +226.94 +236.53 +245.94 +255.18 +264.27 +273.18
30 +218.18 +227.88 +237.41 +246.75 +255.93 +264.95 +273.80
40 +219.21 +228.85 +238.30 +247.58 +256.69 +265.64 +274.42
50 +220.25 +229.82 +239.20 +248.40 +257.45 +266.33 +275.07
60 +221.30 +230.79 +240.11 +249.24 +258.22 +267.04 +275.70
70 +222.35 +231.78 +241.02 +250.08 +258.99 +267.75 +276.35
80 +223.42 +232.77 +241.94 +250.93 +259.78 +268.47 +277.01
90 +224.48 +233.76 +242.87 +251.79 +260.57 +269.19 +277.66
100 +225.56 +234.76 +243.79 +252.66 +261.36 +269.92 +278.33
110 +226.64 +235.78 +244.73 +253.53 +262.17 +270.77 +279.01
120 +227.73 +236.79 +245.68 +254.40 +262.98 +271.41 +279.69
130 +228.82 +237.81 +246.63 +255.28 +263.69 +272.16 +280.38
140 +229.92 +238.84 +247.59 +256.18 +264.62 +272.92 +281.08
150 +231.03 +239.87 +248.55 +257.07 +265.44 +273.69 +281.78
160 +232.14 +240.91 +249.52 +257.97 +266.28 +274.46 +282.49
170 +233.26 +241.96 +250.49 +258.88 +267.12 +275.23 +283.20
180 +234.38 +243.01 +251.47 +259.79 +267.97 +276.01 +283.92
190 +235.51 +244.06 +252.46 +260.71 +268.82 +276.80 +284.64
200 +236.64 +245.12 +253.45 +261.63 +269.67 +277.59 +285.37
210 +237.77 +246.18 +254.45 +262.50 +270.54 +278.39 +286.11
220 +238.91 +247.26 +255.45 +263.49 +271.40 +279.19 +286.85
230 +240.06 +248.33 +256.46 +264.43 +272.28 +280.00 +287.59
240 +241.21 +249.41 +257.46 +265.37 +273.16 +280.82 +288.35
250 +242.36 +250.49 +258.48 +266.31 +274.04 +281.63 +289.11
260 +243.52 +251.58 +259.49 +267.27 +274.92 +282.46 +289.86
270 +244.68 +252.66 +260.52 +268.23 +275.82 +283.29 +290.64
280 +245.84 +253.76 +261.54 +269.18 +276.71 +284.12 +291.40
290 +247.01 +254.86 +262.57 +270.15 +277.61 +284.95 +292.18
300 +248.18 +255.96 +263.60 +271.11 +278.51 +285.79 +292.95
FACTOR eC-1) 104

larazie? ft
in ENGINEERS STANDARD SPECIFICATION
6-71-0057 Rev. 4
oW i :qItgW
n015 . INDIA LIMITED
P17 5rZa S 1) q Goof Inds unlenavng)
FOR PIPELINE MARKERS
Page 1 of 6
1114 Ckch
R, mien flier
FOR
PIPELINE MARKERS
040-12
SPECIFICATION NR MSG VM DM
SPECIFICATION MKM VM AS
2 29.10.01 REVISED & REISSUED AS STANDARD MKM KKS SJ GRR
SPECIFICATION
1 28.09-98 REVISED & REISSUED AS STANDARD KKS RK
SPECIFICATION VC AS
0 19-07-89 ISSUED AS STANDARD SPECIFICATION MK GD SA RCPC
Standards Standards
No Date Purpose Convenor Chairman
by by
Approved by

OWE'? eh ENGINEERS STANDARD SPECIFICATION FOR
'Wag- VW INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
01,7, enreenawn) I A Govt of India Uncleltak.n9)
Page 2 of 6
Abbreviations:

IP Intermediate Pigging
LPG : Liquified Petroleum Gas
RoU : Right of Use

Mr. Raj Kumar
Mr. M. S. Gunjiyal

OR-neeENGINEERS STANDARD SPECIFICATION FOR
$11 051eg viir INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
Page 3 of 6
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 GENERAL 4
4.0 AERIAL MARKERS 5
5.0 KILOMETER MARKERS 5
6.0 PIPELINE WARNING SIGN 5
7.0 RoU BOUNDARY MARKER 5
8.0 DIRECTION MARKERS 6
9.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN 6
10.0 SPECIAL MARKERS 6
REFERENCE DRAWINGS
EIL STANDARD DRAWINGS
7-71-0008 K.M. POST
7-71-0009 TYPICAL ROW BOUNDARY MARKER
7-71-0010 AERIAL MARKER
7-71-0011 DIRECTION MARKER
7-71-0012 PIPELINE WARNING SIGN
7-71-0014 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING

SIGN

002e
efargiINDIA LIMITED
ENGINEERS STANDARD SPECIFICATION FOR
6-71-0057 Rev. 4
IA “thi of Info Undenakiro
PIPELINE MARKERS
Page 4 of 6
1.0 SCOPE
1.1 This specification covers the minimum requirements for supply, fabrication and erection of
pipeline markers to be installed by Contractor at various locations along the route of a cross-
country pipeline.
2.0 REFERENCES
of issue of enquiry) of the following codes:
API RP 1109 : Recommended Practice for Marking Liquid Petroleum Pipeline

Facilities.
Company's Standard Specifications:
6-44-0004 Standard Specification for Shop and Field Painting
Note: In case any Particular Job Specification for Painting is included in the Project
Tender Document, the same shall be applicable in place of Painting specification
mentioned above.
Company's Standards:
7-71-0008 K.M. POST
7-71-0009 TYPICAL ROW BOUNDARY MARKER
7-71-0010 AERIAL MARKER
7-71-0011 DIRECTION MARKER
7-71-0012 PIPELINE WARNING SIGN
7-71-0014 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING

SIGN
3.0 GENERAL
3.1 Contractor shall supply, fabricate and install the Pipeline Markers along the pipeline route.
The location of markers as indicated in the approved drawings shall be treated for guidance
purpose only and the exact location of the markers shall be based on AS BUILT drawings and
as directed by Company.
3.2 The pipeline markers shall be fabricated and installed in accordance with the EIL standard
drawings included herein. Before start of fabrication of the markers, the Contractor shall
prepare and submit for Company's approval, the detailed scheme for the marker plates as
applicable for the project. All the markers shall be painted in accordance with the
requirements of Standard Specification for Shop and Field Painting (Specification No. 6 44
0004). In case of coastal areas the painting on markers shall be suitable for highly corrosive
environment as per Table 10.0, SI. No. 10.2 of specification no. 6 44 0004 and for all other
areas painting shall be suitable for normal corrosive environment as per Table 8.0, SI. No. 8.2
of specification no. 6-44-0004.

laraael ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
5%-4-,41/a9rg, Pane 5 of 6
3.3 The pipeline markers shall be installed, as far as possible, at locations such that they do not
cause any hindrance to the regular use of the land or to the traffic.
4.0 AERIAL MARKERS

Aerial Markers shall in general be installed along the pipeline at every five (5) kilometers
intervals and at places specified by Company.
Refer EIL Standard Drawing No. 7-71-0010 for details.
5.0 KILOMETER MARKERS

Kilometer Markers shall in general be installed along the pipeline at every one (I) kilometer
interval. Markers shall indicate cumulative distance in kilometers from the reference station,
as directed by Company. A kilometer marker is not required, if the relative distance between
its location and any pipeline warning sign is less than 200 meters.
Refer EIL Standard Drawing no. 7-71-0008 for details.
6.0 PIPELINE WARNING SIGN
Pipeline Warning Sign shall in general be installed at:
National and State Highway crossings 2 Nos. min.
Other Road crossings 1 No. min.
Railway Crossings 2 Nos. min.
Minor Water Crossings (less than 15 m width) 1 No. min.
Minor Water Crossings (above 15 m width) 2 Nos. min.
Major Water crossings 2 Nos. min.
Valve Station & IP Station I No. min.
And or any other location as shown in the approved drawings and as directed by the
Company.
Pipeline Warning Sign shall identify the existence of the pipeline and display the name of the
Company, with an emergency telephone number.
7.0 RoU BOUNDARY MARKER
Right-of-Use boundary markers shall be fabricated as per the drawings and shall be installed
at every 250 meters interval along the entire pipeline route. These shall be installed on either
side of the pipeline alignment to define the RoU boundary limits. These shall also be installed
at pipeline turning points to maintain the continuity of the RoU limits.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —AIL rights reserved

-,ark a
Pr LE7 ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED PIPELINE MARKERS 6-71-0057 Rev. 4
T;fen ereetweamnam) (A can of India Undettaingl
Page 6 of 6
8.0 DIRECTION MARKERS
Direction Markers shall be installed to identify the significant Turning Points of the pipeline
during aerial traverse. One direction marker shall be installed at each Turning Point, two more
direction markers shall be installed along the pipeline alignment, one on either side of the
Turning Point at 200 m from the Turning Point.
9.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN
The Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated and installed
one on each bank of navigable water courses at the pipeline crossing location, in lieu of the
Pipeline Warning Sign described in Clause 6.0 of this specification.
10.0 SPECIAL MARKERS
As directed by Company, special markers shall be installed at location where following

changes take place:
Change in pipeline diameter and wall thickness.
Change in type of pipe
Change in class locations for pipelines conveying gas
The above data may be provided on other types of marker (except RoU boundary marker), if
the relative distance between the two does not exceed 100 m.

If'
e_t ENGINEERS
INDIA LIMITED
Go„ oI Ind i a Undertak m91
FOR DOCUMENTATION
FOR PIPELINE CONSTRUCTION
6-71-0059 Rev. 4
Page 1 of 9
41 4011 ^1 1:1 1-1 1u1 * Cti t N;71

* icrki
FOR
DOCUMENTATION FOR
PIPELINE CONSTRUCTION

SPECIFICATION
REVISED & REISSUED AS STANDARD MKM VM AS
SPECIFICATION
1 09-09-98 REVISED & REISSUED AS STANDARD PKM ASr VC AS
SPECIFICATION
Standards Standards
No Date Purpose by by Convenor Chairman
Approved by

15122:rei ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
stgzx takies, INDIA LIMITED
„.o„ sind.unde..„ FOR PIPELINE CONSTRUCTION Pane 2 of 9
Abbreviations:
PIMS : Pipeline Information Management System

RoU : Right of Use

Mr. Raj Kumar
Mr. M. S. Gunjiyal

15dMaeft ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
SigSVS W LNEINtIL
TED
ingi FOR PIPELINE CONSTRUCTION Pa e 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 RECORDS 4
3.0 AS-BUILT DRAWINGS AND PIPE BOOK 6
Format Na 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

OPIZI-e? cc) ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
21 1 INDIA LIMITED
“ 0„ cond...„,„,„, FOR PIPELINE CONSTRUCTION Page 4 of 9
1.0 SCOPE
1.1 This specification covers the minimum requirements of various records, reports and drawings
for all aspects of pipeline construction to be prepared by the Contractor and submitted to the
Company at intervals as described in this specification and as directed by the Company.
1.2 All documents required to be prepared and submitted by the Contractor as per this
specification shall be in addition to the various reports, records, methodology statements,
calculations, drawings etc. to be submitted by the Contractor for Company's record, review or
approval as per the requirements of all other specifications included in the CONTRACT
between the Company and the Contractor.
1.4 Documentation to be submitted by Contractor to Company is summarized below. Number of

Copies (Hard copies / soft copies etc.) shall be as indicated in CONTRACT document.
2.0 RECORDS
The Contractor shall submit to the Company the daily, weekly, monthly reports and after
completion, various other records and reports, for Company's documentation purpose. The
documentation (scheduled reports) shall be submitted progressively during construction. All
às-built' records shall be submitted immediately after the construction. This shall as a
minimum include, but not limited to the following:
2.1 Daily
Separate progress reports of all crews

Daily welding results and repairs
Actual weather conditions
Application for deviations, if any
Accidents
Damages
Activities / approvals required from Company
Materials Receipts
List of urgently required materials
2.2 Weekly
Up-to-date all pipeline data in PIMS

Up-to-date list of confirmed Site Instructions issued by Company
Materials 'taken over' by Contractor
Materials defects and repairs
Outstanding activities of Company
List of installed markers, chainage
Required approval form Company
Progress planned

laraTle ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
INDIA LJMITED
faoleg, FOR PIPELINE CONSTRUCTION Page 5 of 9
Reports of manning of all crews, equipment and plant

Reports of equipment and plant
Reports of accidents
Reports of damages
Reports of Acquired Releases, Permits etc.
Prices variations
Required materials for next month
2.3 Monthly
Project Progress Report, report of payment, safety report, report of accidents, security
reports, health and environment report, material balance, approved deviations.
2.4 Further, Contractor shall apply for approval, if required, to the Company with document such
as but not limited to:
Organogram for construction of work

BM-data of key personnel (including foremen)
(Revised) list of address of personnel in particular of medical staff, safety and security
officers.
(Revised) list of approved coaters
(Revised) list of approved sub-Contractors
Time schedule
Acquired permits and/or approval from Authorities, if any.
Minutes of meeting with Company with comments, if any.
Material certificates, material receipt.
Guarantees from Vendors and sub-Contractors
Calculations for temporary works, buoyancy, blasting, pipe pulling etc.
Drawings issued by Contractor.
Vendor drawings.
As-built drawing of route maps, alignment sheets, detail drawings and isometric
drawings,
Procedures such as surveying, stacking, fencing.
Welding procedure qualification record, radiographic procedure qualification, welder
qualification
Coating and repair procedure.
Installation of crossings.
Hydrostatic testing Procedure
Blasting Procedure
Radiographic report along with original radiographs
Pipe and welding book
Material records and Accounting book

ENG INEERS
INDIA LIMITED
FOR DOCUMENTATION
6-71-0059 Rev. 4
Govt FOR PIPELINE CONSTRUCTION Paa e 6 of 9
Reports
Material tests (coating, welding, painting)
Computerised Potential Logging Test
Water samples
Cleaning, Pigging Report before hydrostatic test
Hydrostatic test
Calibration test
Blasting trials
Equipment certificates (dead weight tester, instruments, vessels, equipment)
Manuals
Major water crossings
Waster disposal
Disposal of water after hydrostatic test.
2.5 The Contractor shall submit to Company, colour photographs (hard copy as well as digital
format) taken through digital camera (having resolution >1 mega pixels) of various
construction activities/operations at regular intervals. Size, number and frequency of the
photographs shall be mutually agreed upon between the Contractor and the Company. The
Contractor shall make video recordings of all operations right from the start of construction till
the completion of the work, covering to the extent as instructed by Company and submit to
Company. The recordings shall be made progressively as construction advances. Upon
completion of the work, the Contractor shall submit the recordings in CD / DVD or any other
format specified by the Company. The duration of each video recording shall be of 1/2 hour
(unless specified otherwise) and shall cover all major aspects of the job.
3.0 AS-BUILT DRAWING AND PIPE BOOK
3.1 General
The Contractor shall prepare "As-built' drawings of all the drawings, whether issued by
Company or prepared by Contractor including vendor drawings, such as but not limited to:
For pipeline section:
Route maps
Alignment sheets
Detailed drawings (road, railway, minor water crossings, major water crossing, valley
crossings, utility crossings, cable crossings)
Isometric drawings of installations
Special installation.
Further Contractor shall prepare a pipe book.
If required by the Company, the Contractor shall update the drawings issued for construction
of the job.

laltre?gth ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
511gar RitegliPINDIA LIMITED FOR PIPELINE CONSTRUCTION
Page 7 of 9
3.2 "As-built" Drawings
The Contractor shall prepare a complete set of "As-built" drawings. From the start of
construction, the Contractor shall, on daily basis, process any changes in two sets of drawings.
Deleted parts shall be indicated in red, new parts in blue, remarks in green and unchanged
parts in yellow. Said drawings shall be kept at site and shall be available to Company at all
times. The Contractor shall prepare "As-built" drawings based on these data. On completion of
the work, revised drawings made "As-built" by Contractor shall be handed over to Company.
The Hard Prints shall be submitted in As-Built Dossier and Soft Copies shall be submitted in
CD / DVD format.
The Contractor shall prepare and submit a specimen of the layout of the drawings for
Company's approval.
The required measurement for "As-built" drawings shall be executed by the Contractor by
experienced and qualified surveyors.
The surveyors shall daily take care of all measurements required such as but not limited to:
Horizontal location of pipeline with regard to deviation and Permanent Grid Pillars.
Vertical level with regard to Mean Sea Level of pipeline and grade.
Location and type of bends, fittings etc. and grades, points of intersection.
Changes of wall thickness, materials.
Location and details of valves, insulating joints, fencing.
Location and details of road, railway, water crossing, suspension bridges.
Location and details of casing pipes, vents.
Location and type of coating.
Location and type of weighing, anchoring.
Location and type of markers.
Location of further appurtenances (Pig-signallers).
Location of RoU and of pipeline with respect of RoU.
Type of soil.
Type of rock.
Type of blasting and ripping
Sand padding.
Type of road pavement.
Details of bank protection, number of insulators, seals.
The Contractor shall also prepare isometric drawings of installation (facilities) etc. for which
the data as mentioned in or required for the Pipe and Welding Book can be identified and these
drawings can also be used for material accounting.
3.3 Name plates of Equipment
All permanent equipment supplied and installed by Contractor shall be provided with plates by
Contractor. All texts shall be submitted to Company for approval before plates may be
manufactured.

OIIRTAft ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
Sigar laWWW
INDIA LIMITED
(.. FOR PIPELINE CONSTRUCTION Page 8 of 9
3.4 Pipe Book
Every page of the Pipe and Welding Book shall mention:
Data relevant to the project and section thereof

Sequential number
Length brought forward (for pipes and other materials).
Length to bring forward (for pipes and other materials)
Alignment sheet number and at least the location thereon of two welds on every page
of the Pipe Book.
Further, following shall be specified:
Diameter of pipeline
Length of each pipe
Wall thickness
Pipe number
Heat number, certificate number
Cut and re-numbered pipe ends
Coating
Date of stringing
Data of welding
Direction of working
Weld number
Welder number
Type of welding, electrodes, diameter of electrodes etc.
Heat treatment
Equipment used for radiography
Limits of water crossings.
Test pressure and date of test.
In order to achieve this, the Contractor shall identify all pipe elements. Sample format of Pipe
Book shall be submitted for Company approval.
3.5 As-Built Documents
The Contractor shall prepare all documents in the prescribed format as indicated below. In
addition to the hard copy, soft copies of final documents shall also be submitted in electronic
media i.e. CD / DVD format.
Software used for the preparation of these documents shall be as follows:
Type of document Software
Reports MS Word (Office 2007 or above)

Drawings AutoCAD (Release 2010 or above)

101 e..1 a ENGINEERS FOR DOCUMENTATION 6-71-0059 Rev. 4
,,,,wwiANITN■dpsenzED FOR PIPELINE CONSTRUCTION
Stg-istlayeu Page 9 of 9
For the purpose of preparation of As-built drawings, Contractor shall update the "Issued for
Construction" drawings issued by the Company. It shall be the Contractor's responsibility to
convert the drawings furnished by the Company in hard copy into AutoCAD drawings
including scanning, digitising and converting the drawings into a suitable format compatible
with the AutoCAD Release 2010 or above. As-built drawings shall be prepared only on
AutoCAD Release 2010 or above.

ENGINEERS STANDARD SPECIFICATION
INDIA LIMITED FOR BLASTING 6-71-0061 Rev. 3
(A Gout. of India Undertakng) Page 1 of 10
att.") di
fug tritvr
FOR
BLASTING
REVISED & REISSUED AS STANDARD ti— kt"5- 124441t

3 18.07.11 SPECIFICATION RK VM DM
REVISED & REISSUED AS STANDARD MKM DD AS VJN
REVISED & REISSUED AS STANDARD LD ASr VC AS
0 09.06.89 ISSUED AS STANDARD SPECIFICATION MK GD RKD/SA
Standards Standards
No by by
Approved by

401 ENGINEERS STANDARD SPECIFICATION
Oileg,INDIA LIMITED FOR BLASTING 6-71-0061 Rev. 3
IA Govt of India UnOettaking)
Page 2 of 10
Abbreviations:
BS British Standard
IS : Indian Standard
NFPA : National Fire Prevention Association
Members : Mr. Raj Kumar

Mr. M.S. Gunjiyal
Mr. Atul Chhatwal
Dr. R.S. Bhatia (Piping)
Mr. S.S. Lotay (Inspection)

Itg7
lanes
INDIA LIMITED
IA Govt of India UndeItak,n9)
FOR BLASTING 6-71-0061 Rev. 3
Page 3 of 10
CONTENTS
1.0 SCOPE 4
3.0 GENERAL 3
4.0 MATERIALS 5
5.0 PERSONNEL 6
6.0 STORAGE OF EXPLOSIVES 6
7.0 PREPARATION OF EXPLOSIVES 7
8.0 PREPARATION OF PRIMERS 8
9.0 CHARGING OF HOLES 8
10.0 ELECTRICAL FIRING 8
11.0 VIBRATION RECORDING .9
12.0 MISFIRES 9
13.0 DISPOSAL OF DETERIORATED EXPLOSIVES 10

dolENGINEERS STANDARD SPECIFICATION
5=gzir laigies INDIA LIMITED FOR BLASTING 6-71-0061 Rev. 3
144,7n 292,15feanXigrral IA GoN of India U ndeItaA..9)
Page 4 of 10
1.0 SCOPE
1.1 This specification covers the minimum requirements for materials, personnel, transportation,
storage and use of explosives for grading of Right of Use (RoU) and excavation of trenches
for onshore pipeline installation in rocky terrain.
1.2 This specification does not cover the construction or operation of permanent magazines.
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.
BS-5607 Safe use of Explosives in the Construction Industry
IS-4081 Safety Code for Blasting and Related Drilling Operations
NFPA-495 Manufacture, Transportation, Storage & Usage of Explosive

Materials.
Safety Rules of Chief Controller of Explosives, Nagpur
3.0 GENERAL
3.1 The Contractor shall acquaint himself and comply with all the applicable local laws and
regulations concerning storing, handling and the use of explosives. All such laws, regulations
and rules etc., as enforced from time to time shall be binding upon the Contractor.
National/Local Laws and Regulations shall take precedence over this specification in the event
of conflict. All conflicts shall be brought to the notice of the Company.
3.2 The requirements stated herein however in no way relieve the Contractor of his responsibility
of carrying out safe blasting operations. The Contractor shall be solely responsible for
damages and claims thereof.
3.3 The use of explosives requires an approval from the Chief Controller of Explosives and/or his
authorized Inspector. It shall be the responsibility of the Contractor to obtain all such permits
and approvals and comply all requirements regarding the safe storage, handling and use of
explosives. All expenses incurred in this regard shall be to Contractor's account.
3.4 Contractor shall inform the Company in writing at least four (4) weeks prior to planned use of
explosives.
3.5 Contractor shall notify the Company prior to any blasting in the proximity of overhead power
lines, roads, communication lines, pipelines, utility services or other services and structures
above and below ground. Before, start of blasting operations, local authorities and owners of
utilities shall be consulted to check on the presence of services, which could be damaged and
their approval obtained to undertake blasting operations. The distances to nearest structures
(houses, offices, factories) or service shall also be taken into consideration when planning
blasts so that ground vibration and air-over pressure is kept within acceptable levels as given
in section 11.0 of this specification
3.6 Contractor shall prepare an Explosives Handling and Usage Procedure for the information of
the Company, which shall include the following:
Detailed procedure and calculations

Copyright EIL —All rights reserved
■31 ENGINEERS STANDARD SPECIFICATION
Ifgar 22-eg
Rife, 070,17 MI Mimi)
INDIA LIMITED
(A Govt of lode Undo! talong )
FOR BLASTING 6-71-0061 Rev. 3
Page 5 of 10
Nature of blasting operations, including hole diameter, depth and presence of cavities
Rock characteristics
Type of explosives
Temperature likely to be encountered in use
3.7 Unless specified otherwise, blasting shall not be allowed within 20 m range of any above
ground or underground structure, pipelines or other facilities. However, in case it is necessary
to carry out blasting operation within 20 m range from any under ground or above ground
structures, pipelines or other facilities, the blasting may be allowed, at discretion of Company,
subjected to the following:
Minimum clear distance from the facility shall be 5 m.
Contractor demonstrates the blasting technique proposed by him doesn't result in any
damage to the existing facility. (Contractor shall carry out mock demonstration as per
the direction of Company Representative for this purpose).
Contractor fulfills the conditions laid out by the Owner of the existing facilities.
Contractor fulfills the requirements laid out by National/Local Laws and Regulations
and other statutory/regulatory Authorities.
In case of presence of overhead power lines/cables, specific approvals shall be obtained by

Contractor from the concerned Authorities having jurisdiction over it.
4.0 MATERIALS
4.1 All materials such as explosives, detonators, fuses, tamping materials etc. that are proposed to
be used by the Contractor in blasting operations, shall be as approved for use in the Country.
4.2 All electric detonators used in the blast shall be of the same electrical sensitivity and be
produced /procured from the same manufacturer.
4.3 The detonators used shall be capable of giving effective blasting of the explosives. Damaged
explosive materials shall be destroyed by a responsible person as per manufacturer's
instructions or returned to the manufacturer.
4.4 No explosive material shall be left abandoned at any place.
4.5 All blasting materials and testing equipment shall be regularly tested for correct performance.
The intervals between test shall be decided after consideration of the local factors, but tests
shall always be carried out if the blasting materials and/or test equipment have been subjected
to abnormal conditions, or following any misfires. Guidelines/recommendations of the
manufacturer shall be adhered to.
4.6 All packaging and other waste materials gathered together during blasting operation shall be
burnt after the blast has been fired. The burning site shall be chosen at a safe distance with due
respect to prevailing wind strength and direction, at least 100 meters from explosives stores
and other premises. A minimum of two fire extinguishers shall be on hand during burning
activities.

Ifear ElfRes INDIA LIMITED FOR BLASTING 6-71-0061 Rev. 3
OW, eiETIK• Munr.1) IA Gout of India Undenalong)
Page 6 of 10
5.0 PERSONNEL
5.1 Excavation by blasting will be permitted only under personal supervision of competent and
licensed persons and by trained workmen.
5.2 The storage of explosives shall be in the charge of a person approved by the Company.
Company may, if necessary, ask police inquiries being made as to his reliability, antecedents
etc.
6.0 STORAGE OF EXPLOSIVES
6.1 The Contractor shall build a magazine for storing the explosives. The site of the magazine, its
capacity and design shall be subject to approval by the Company and the Inspector of
Explosives before the fabrication is taken up. As a rule the explosives should be stored in a
clean, dry, well ventilated, bullet proof and fire proof building, at an isolated site. Adequate
security shall be provided to ensure no unauthorized entry into the magazine. A notice shall be
hung next to magazine entrance prohibiting entry of unauthorized persons.
6.2 Contractor shall comply with National/Local Regulations and specifications for truck mounted
mobile explosives store. Mobile stores shall only carry ONE DAY's Explosives requirements
and shall be parked overnight inside the compound at the authorized magazine.
6.3 All safety precautions and necessary equipment for maintenance, operation of mobile stores,
as required by local authorities or regulatory bodies shall also be installed/provided on the
Mobile Store.
6.4 A careful and day-to-day account of all explosives shall be kept by the Contractor in a register
and in an approved manner. The register shall be produced by the Contractor, for the
inspection of the Company/Inspector of Explosives when so required by the later.
Any loss, damage or theft shall be reported immediately to the necessary local authorities and
to the Company.
6.5 The magazine shall on no account be opened during or on the approach of a thunderstorm and
no person shall remain in the vicinity of the magazine during such period.
6.6 Magazine-shoes without nails shall, at all times, be kept in the magazine, and a wood-tub or
cement trough, filled with water shall be fixed near the door of the magazine.
6.7 Persons entering the magazine must put on the magazine-shoes and shall comply to following:
Not to put their feet on the clean floor unless they have magazine-shoes on.
Not to allow the magazine-shoes to touch the ground outside the clean floor.
iii) Not to allow any dirt or grit to fall on the clean floor.
6.8 No matches or inflammable material shall be allowed in the magazine. Light shall be obtained
from an electric storage battery lamp.
6.9 No person having articles of steel or iron on him shall be allowed to enter the magazine. No
tools or implements other than those of copper, brass, gun metal or wood shall be allowed
inside the magazine.
Oily cotton, rags, waste and articles liable to spontaneous ignition, shall not be allowed inside
the magazine.

ligar faajeg INDIA LIMITED FOR BLASTING 6-71-0061 Rev. 3
?rallIV Qn 3,70571) IA Govt of India Undeltaking)
Page 7 of 10
6.10 Boxes of explosives shall not be thrown down or dragged along the floor and shall be stacked
on wooden trestles. Open boxes of explosives shall never be exposed to the direct rays of the
sun. Empty boxes or loose packing materials shall not be kept inside the magazine.
6.11 The magazine shall have a lightning conductor, which shall be got tested periodically, by an
officer authorized by the Company, the testing fee shall be to the Contractor's account.
6.12 The magazine shall be inspected periodically by an officer representing the Company, who
will see that all the rules are strictly complied with. He will notify all omissions etc. to the
Contractor, who shall rectify the defects within a period of 3 days from the date of receipt of
the notice, failing which the Company may take whatever actions it considers suitable.
7.0 PREPARATION OF EXPLOSIVES
7.1 Contractor shall submit the following procedures for INFORMATION of the Company as a
minimum.
Loading of explosives
Drilling of new holes and extending existing holes
Handling of explosives at site
Tamping explosives into holes
Machines, tools and cables required
Initiation of blasting
Safety of personnel
Vibration control
Blast pattern and shot size establishment
Misfires
Emergency procedures
7.2 Trial blasts in conjunction with vibration recording shall be carried out for each rock and
trench type, in order to assess rock breakability and vibration levels. These trial blasts shall be
carried out prior to actual trench blasting of the pipeline route. Contractor shall conduct trial
digs as directed by Company in order to check suitability of the blasting pattern and to
measure vibration levels to ensure vibration levels are below the allowable maximum.
7.3 "Weight per Distance Tables" shall be drawn up from these trials.
7.4 The detonators shall never be forced into the primer cartridge. It shall be inserted in a hole
made by a wooden, copper, brass or aluminum pricker. The detonator shall be firmly
embedded in the primer so that it is not pulled out of place during loading.
7.5 Detonators shall be activated electrically. In proximity of electric over-head power lines,
Contractor may use non-electric system with the approval of Company. Fly rock shall be
minimized by the use of approved blast mats and by careful selection of shot size and drill
hole configuration.

101
Ifea 05Eleg
ENGINEERS
INDIA LIMITED
6-71-0061 Rev. 3
(Wert orfooff7frisfcrott (A Govt of India Unclettahong)
FOR BLASTING
Page 8 of 10
7.6 Use of explosives is prohibited in areas exposed to flammable gasses or dust.
7.7 Explosive and detonators shall be carried in separate boxes, tightly closed, and transported
separately. For the conveyance of primers special containers shall be used.
7.8 Explosives shall be stored and used chronologically to ensure that the ones received earlier are
being used first.
7.9 A make-up house shall be provided at each working place in which cartridges shall be made
up by experienced men as required. The make-up house shall be separated from other
buildings. Only electric storage battery lamps shall be used in this house.
7.10 No smoking shall be allowed in the make-up house.
8.0 PREPARATION OF PRIMERS
The primers shall not be prepared near open flames or fires. The work of preparation of
primers shall always be entrusted to the qualified and approved personnel. Primers shall be
used as soon as possible after they are ready.
9.0 CHARGING OF HOLES
9.1 The work of charging shall not commence before all the drilling work at the site is completed
and the Company has satisfied itself to that effect by actual inspection.
9.2 The lead wires shall be kept away from conductors or sources of stray current, while charging,
open lamps/flames shall be kept away.
9.3 Only wooden tamping rods without any kind of metal on them shall be used.
9.4 Only one cartridge shall be inserted at a time and gently inserted to the required depth with the
tamping rod. The sand, clay or other tamping material used for filling the hole completely
shall not be tamped too hard.
9.5 Blasting shall not take place after sunset or before sunrise unless specific approval is first
obtained by Contractor from local authorities and the Company.
9.6 The site of blasting operations shall be prominently demarcated by red danger flags. The order
of fire shall be given only by the Supervisor-In-Charge of the work and this order shall be
given only after giving the warning signal three times, so as to enable all the labor, watchmen
etc. to reach safe shelter and after having ascertained that nobody is within the danger zone.
9.7 A buegle with a distinctive note shall be used to give the warning signals. The buegle shall not
be used for any other purpose. All the labor shall be made acquainted with the sound of the
buegle and shall be strictly warned to leave their work immediately at the first warning signal
and to take safe shelters, and not to leave the shelters until the all clear signals have been
given.
9.8 All the roads and footpaths leading to the blasting area shall be watched. All the escape routes
shall have been clearly marked.
10.0 ELECTRICAL FIRING
10.1 Only the Supervisor-In-Charge shall keep the key of the firing apparatus and shall keep it
always with himself.

dol ENGINEERS STANDARD SPECIFICATION
elf 02ft INDIA LIMITED FOR BLASTING 6-71-0061 Rev. 3
2920,174713,14F.1) (A Govt of India Undeftakm9)
Page 9 of 10
10.2 Special apparatus shall be used as source of current for the firing operations. Power lines shall
not be tapped for the purpose.
10.3 The firing cable shall have a proper insulating cover so as to avoid short circuiting due to
contact with water, metallic parts or rock.
10.4 The use of earth as a return line shall not be permitted.
10.5 The firing cable shall be connected to the source of current only after ascertaining that nobody
is in the area of blasting.
10.6 Before firing, the circuit shall be checked by a suitable apparatus.
10.7 After firing, whether with or without an actual blast, the contact between the firing cable and
the source of current shall be cut off before any person is allowed to leave the shelter.
10.8 During storms, charging with electrical detonators shall be suspended. The charges already
placed into the holes shall be blasted as quickly as possible after taking all the safety
precautions and giving necessary warning signals. If this is not possible, the site shall be
abandoned till the storm has passed.
11.0 VIBRATION RECORDING
11.1 Contractor shall use Company approved vibration recording system capable of measurement
in three axes (tri-axial). The device shall have an accuracy of 0.0025 mm and a resonance of 2
Hz.
- The device shall measure both frequency and amplitude of vibration.
11.2 All the measurement devices shall be calibrated by an APPROVED certification body.
11.3 Particle velocity shall not exceed the following:
11.3.1 Areas beyond 500 m of proposed pipeline centreline
- 50 mm/sec at a surface distance of 15 m from trench centerline.
11.3.2 Areas with existing buried or above ground facilities within 500 m of proposed pipeline
centerline
- 20 mm/sec at a surface distance from the trench centreline towards the nearest existing
facilities.
11.4 The particle velocity levels are provided for the guidance only, Contractor shall be responsible
and liable for any injury to life or damage to property/facilities.
11.5 Air-over pressure/sound levels shall be limited to 100 db in inhabited areas.
12.0 MISFIRES
12.1 If it is suspected that part of the blast has failed to fire, or is delayed, sufficient time shall be
allowed to lapse before entering the danger zone. When fuse and blasting caps are used, a safe
time should be allowed and then the Supervisor alone shall leave the shelter to see the misfire.
12.2 Drilling near the hole that has misfired shall not be permitted until one of the two following
operations have been carried out by the Supervisor:

rEr ENGINEERS
D INDIA STANDARD SPECIFICATION
6-71-0061 Rev. 3
/01
/fgaT5teg
rawerr erlianlaas Jal7rin
LIMITED
(A Gook of India Undertaking)
FOR BLASTING
Page 10 of 10
The Supervisor should very carefully (when the tamping is of damp clay) extract the
tamping with a wooden scraper or jet of water or compressed air (using a pipe of soft
material) and withdraw the fuse with the primer and detonator attached. A fresh
primer and detonator with fuse shall then be placed in this hole and fired.
The Supervisor shall get one foot of the tamping cleaned off and indicate the direction
by placing a stick in the hole. Another hole may then be drilled at least 9" away and
parallel to it, this hole should then be charged and fired. The balance of the cartridges
and detonators found in the muck shall be removed.
12.3 The Supervisor shall at once report to the office all cases of misfire, the cause of the misfire
and the steps taken in connection therewith.
12.4 If a misfire has been found to be due to defective detonator, or explosive, the whole quantity
from the box from which the defective articles were taken must be returned to the
manufacturer for inspection to ascertain whether the whole box contains defective materials.
12.5 Re-drilling the holes that have misfired either wholly or partly shall not be permitted.
13.0 DISPOSAL OF DETERIORATED EXPLOSIVES
All deteriorated explosives shall be disposed off in an approved manner. The Contractor shall
prepare said disposal plan, which shall be approved by Company/Local Authorities/Controller
of explosives. The quantity of the deteriorated explosives to be disposed off shall be intimated
to Company prior to its disposal. All the records of such disposal shall be maintained by
Contractor.

ataadhe ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
Igar afilegNIE INDIA LIMITED (ONSHORE)
IA Got 0/ India unleptaxingi Page 1 of 24
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REVISED AND REISSUED AS STANDARD
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Standards Standards
No by by
Approved by

safrzeigh ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
5'ga Wift INDIA LIMITED (ONSHORE) Page 2 of 24
Abbreviations:
BM Bench Mark
DGPS Differential Global Positioning System
DTM Digital Terrain Modelling
EDM Electronic Distance Measurement
GPS Global Positioning System
GWT Ground Water Table
IP Intermediate Point
NGL Natural Ground Level
ROU Right of Use
SPT Standard Penetration Test
TP Turning Point
UTM Universal Transverse Mercator

Mr. Raj Kumar
Mr. M.S. Gunjiyal
R. Chaudhury (SMMS)
Mr. A. K. Chaudhary (Inspection)

FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
CONTENTS
1.0 SCOPE
2.0 REQUIREMENTS
3.0 DOCUMENTATION
APPENDIX-A PIPELINE ROUTE CENTRELINE SURVEY

APPENDIX-B DETAILED ROUTE SURVEY
APPENDIX-C SOIL INVESTIGATION SURVEY
APPENDIX-D LOCATION CLASS SURVEY
APPENDIX-E CADASTRAL SURVEY
ANNEXURE-I PIPELINE ROUTE SURVEY DATASHEET

ANNEXURE-II SAMPLE FORMATS

1.0 SCOPE
This specification covers the minimum requirements for various type of surveys required to be
carried out for an onshore pipeline. The requirements for surveys and investigations related to
locating pipeline route centreline, dumpsites and intermediate station/terminal facilities on
ground, obtaining topographic features, ground profile and soil data along the pipeline route;
collection of revenue maps/ data and preparation of cadastral maps for ROU/Land acquisition
purposes; collection of location class data along the pipeline route are specified in this
specification.
The specification also covers requirements related to construction of survey monuments, field
measurements and presentation of survey data including preparation of maps, drawings,
documents and reports.
2.0 REQUIREMENTS
2.1 All survey works shall be performed by and/or under the direct supervision of a qualified land
SURVEYOR.
2.2 All survey work shall be carried out using modern and well-maintained survey
equipments/instruments such as DGPS, GPS, EDM, Total Station, Theodolite, Inclinometers
and any other equipments/instruments deemed necessary for completion of works as per this
specification.
2.3 Following type of surveys are covered under this specification:
Pipeline route centreline survey as per Appendix-A.
Detailed pipeline route survey as per Appendix-B
Soil investigation surveys as per Appendix-C
Location class survey as per Appendix-D
v) Cadastral survey as per Appendix-E
Specific requirements of surveys for a particular project shall be as indicated in CONTRACT.
2.4 Normally detailed route survey shall be carried out after centreline survey has been completed
and the pipeline route established on ground has been accepted by the Company. In case the
pipeline route has already been identified by the Company and/or the centreline survey is not
required to be carried out by the survey contractor, the SURVEYOR shall make himself fully
aware of the general conditions of the terrain along the pipeline route prior to start of survey
work.
2.5 In case, the pipeline for which the route survey is proposed to be carried out is to be used for
transportation of hydrocarbons in gaseous phase, the location class survey shall be carried out
as per Appendix-D of this specification.
2.6 All major crossings and routing in critical areas shall be finalized by SURVEYOR in
consultation with Company/Engineer-in-Charge. Company may depute its representative
during the survey work to assist the contractor in finalizing such location at its sole discretion
2.7 The SURVEYOR shall avoid major deviations from identified/established route during
detailed survey. Any such major deviation must be approved by Company representative.

lallaaeg at, ENGINEERS FOR PIPELINE SURVEYS
sign EtWerdif INDIA LIMITED
w, Goys ot YW umertang■ (ONSHORE)
6-71-0071 Rev. 3
Page 5 of 24
SURVEYOR shall clearly specify reasons for such deviations while submitting his proposal
for change in route.
2.8 When so specified in contract document the SURVEYOR shall locate dump site(s), for
storage of line pipe and other pipeline materials, along pipeline route.
Unless specified otherwise in data sheet/ contract document the dumpsite(s) shall be located at
75-100 km interval and shall have an area of 5 — 10 hectares.
Following aspects shall be taken into account while selecting dumpsite location(s):
Dumpsite should preferably be a barren land free from water logging/low lying areas.
The site shall be located in close proximity of identified/established route.
It should be in the vicinity of National/State Highway.
The site should be nearly flat with minimum undulation that might require earth work
(fill-up and earth-cutting).
Site should not be under overhead powerlines.
Site should preferably be on government land.
3.0 DOCUMENTATION
3.1 Maps & Drawings
All maps and drawings shall be made using standard formats enclosed with this specification.
The SURVEYOR shall perform all mapping and drawing work so as to contain all relevant
data consistent with the survey notes and observations. The type of drawings and maps to be
prepared shall be as per requirements specified under Appendix-A to Appendix-E.
3.2 Reports
The reports to be prepared by SURVEYOR shall be exhaustive and shall contain all relevant
information. The report shall describe in brief the survey methodology adopted, equipment
used and tests (if required) conducted for obtaining the details/data presented in the report.
The final results/conclusion shall be based on sound practices and detailed analysis of the data
collected. The report must include recommendations as applicable for the Company's
consideration.
3.3 Drawing/Document Submission
All drawings and document shall be prepared using computers. Hard copies and soft copies of
all required drawings and documents shall be submitted to Company for review/approval. The
Company shall review and comments, if any, shall be passed on to the SURVEYOR. The
SURVEYOR shall incorporate all comments, including carrying out fresh field
works/laboratory testing (when required) and revise the drawing/document to entire
satisfaction of Company. Number/sets of hard copies and soft copies of each drawing and
document (submitted for review/comments by Company) shall be as indicated in
CONTRACT.
Once the drawing/documents have been reviewed by the Company and updated by surveyor to
entire satisfaction of Company, the SURVEYOR shall submit entire documentation
(drawings, maps, reports etc.) both in hard copy as well as soft copies for Company's records

15Mag e
e ENGINEERS FOR PIPELINE SURVEYS
s'fgar faittgw , WA LIMITED
(ONSHORE)
6-71-0071 Rev. 3
Go„ 01 inch, undersingi Page 6 of 24
(number of copies as specified in CONTRACT). All hard copies shall be signed and stamped
by SURVEYOR. All drawings and sketches shall be prepared using AutoCAD Release 2012
or above. All reports/documents shall be prepared using Microsoft Office Release 2012 or
above. All photographs included in document/reports shall also be in digital format
(JPG/TIFF). Whenever data base is used for presentation of data (location class, ground
profile etc.), the same shall be prepared in Access Data Base Software using Microsoft Office
Release 2012 or above.
Pipeline route maps shall also be furnished with ".KML & .KMZ" files. Additionally, the
complete pipeline route maps in ".KML" file shall be furnished with video files demonstrating
topographical features with limits of ROU & class locations and major crossing such as
Highways, Railways, Canals, Rivers and Forest etc. All crossings shall be linked with
photographs indicating chainage, name of crossing etc. in the video.

OSillnlaeTa ENGINEERS FOR PIPELINE SURVEYS
7 Emegwi, INDIA LJMITED
salg 6-71-0071 Rev. 3
+wenefeawoonJoom/ IA GoA of M ph lindenalong) (ONSHORE) Page 7 of 24
APPENDIX-A
PIPELINE ROUTE CENTRELINE SURVEY
1.0 Objective
The objective of the centreline survey work is
Physical verification of the identified route and confirm its suitability for pipeline
construction.
Identify restrictive areas and suggest modifications/detours to the identified route
Establish the route on ground.
Collection of development plans along the proposed pipeline route from various agencies
having jurisdiction thereof.
v. Collecting information required for obtaining clearances from various authorities

including environmental clearances.
2.0 Requirements
2.1 General
2.1.1 The Company shall provide the SURVEYOR identified pipeline route details.
2.1.2 The SURVEYOR shall transfer the Company identified route onto Survey of India (Sol)
topographic maps or Satellite imageries (in scale 1:250,000, 1:50,000 or less in case identified
route passes through hilly/ghat areas) for use during field verification and preparation of route
maps. The maps for this purpose shall be arranged by SURVEYOR unless specified otherwise
in contract. For section of the identified pipeline route covered in maps identified/declared by
Sol as "Restricted" maps, Company may arrange such maps and make them available to the
SURVEYOR during field verification. SURVEYOR may also use satellite imagery for
updating of SoI maps, if required, as per provisions of CONTRACT document.
2.1.3 SURVEYOR shall carryout reconnaissance survey as necessary to orient the most practical
alignment along identified route using best judgement and experience of the SURVEYOR to
interpret the needs of pipeline construction. The SURVEYOR shall use Global Positioning
System (GPS) and other survey equipment such as magnetic compass, inclinometer, theodolite
etc. as required during the reconnaissance survey.
2.1.4 The SURVEYOR shall locate and identify all existing features and obstructions along the
route, identified by Company, and within a corridor of 5 km on either side of centreline that
are not shown in the available maps and update the Sol maps to reflect such changes.
SURVEYOR shall collect all development plans from the concerned authorities.
2.1.5 SURVEYOR shall establish stakes/mark flag control points on ground along the centreline of
route. Flag control points shall be clearly identified on the route maps. The flag control points
shall also be established at all major road, rail, canal (lined/unlined), pipeline, river crossings
and terminal locations.

151012:Re ENGINEERS FOR PIPELINE SURVEYS
sifta kitOlegNie INDIA LIMITED 6-71-0071 Rev. 3
IA Gort of India UndegtWing) (ONSHORE) Page 8 of 24
2.2 Pipeline Route Deviation
221 SURVEYOR in general shall avoid any major deviation from the route identified by
Company. Deviation from route, if considered essential by the Contractor, shall be brought to
the notice of the Company representative for Company's approval.
2.2.2 Contractor shall avoid obvious man made or natural obstructions such as culverts, bridges,
utility poles, building/structures, gorges, plantations, archaeological sites, reserve forest, wild
sanctuaries, environmental sensitive areas, mining sites, future built-up areas etc.
2.2.3 SURVEYOR shall take into account following criteria while selecting pipeline route
alignment in hilly areas/ghat regions etc.
A longitudinal slope along pipeline route shall not exceed 1:5
A transverse slope across pipeline route shall not exceed 1:1
c. As far as possible ridges/spurs should be used to climb up/come down from hill. Side
slopes of hills requiring excessive side billing should be avoided.
Hand held inclinometer shall be used for estimation of slopes
2.2.4 Centreline alignment thus established shall be shown prominently on the route maps. In
addition chainage in km, major turning points, intermediate facilities, planned developments,
existing features/obstructions, flag control points etc. shall also be marked on route maps.
2.3 Field Marking
2.3.1 The entire length of the surveyed route shall be staked on ground along the proposed
centreline. Stakes shall be 8 mm dia. painted twisted rods. Sketches/photographs to facilitate
location of stakes in field shall be furnished giving reference of existing features wherever
major directional change takes place.
2.3.2 Stakes shall be installed at flag control points, major crossings, major turning points and at an
approximate 1.5 to 2.0 km interval as dictated by field conditions.
2.3.3 Consideration shall be given to land use in placing the stakes e.g. stakes placed and left in
cultivated land may not be acceptable to the land owner. Stakes in such areas shall be placed
at boundaries between cultivated areas where necessary.
3.0 Presentation of survey data
Centreline survey data shall be presented in the form of following drawings/documents:
Pipeline route map showing route on SOI Topo sheets or satellite imageries of scale
1:50,000 or 1:25,000 for unrestricted areas. (SOI topo sheets shall be updated for
distance of 5 km on either side of pipeline centreline).
Pipeline route maps showing route on maps developed from SOI topo sheets or
satellite imageries of 1:50,000 or 1:25,000 scale for areas covered in "Restricted" 501
maps.
c. Overall pipeline route map in 1:500,000 scale.

ISiazida ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
lgar Ellateg W INDIA LIMITED (ONSHORE) Rape 9 of 24
d. Ground profile drawing and ground elevation v/s pipeline chainages in MicroSoft
Access software (ground elevations to be furnished on an average at every km interval
or at locations where major change in ground elevation occurs).
e) Route report consisting of but not limited to following:
Route Description
Topographic features
Major Crossing details
Extent of reserve forest
Land use pattern and soil strata along route.
Developments plans
Estimates for land cost for RoU acquisition.
General metrological details
Site photographs. (Photographs shall be sufficient in numbers to represent the

entire terrain features).
Dump site locations suitable for pipe storage (when specified)
Ground Profile along the route
(xii) Comparison of alternative routes considered.

ISIWieg a ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
ltgar Elf5legYe INDIA LIMITED (ONSHORE)
•iRlfrecIASOM)
own IA Goof of inda unentamong) Page 10 of 24
APPENDIX-B
DETAILED ROUTE SURVEY
1.0 Objective
Objectives of detailed pipeline route survey are as follows:
To fix the pipeline alignment on ground.
To determine exact pipeline route length.
Finalize crossing locations and crossing angles.
Establish survey monuments on ground along pipeline route.
To obtain detailed topographic features within 30 m on either side of centreline.
To obtain ground levels and/or contours.
To obtain cross-section details and topographic features at all crossings.
To gather details of land use pattern and soil characteristics
2.0 Requirement
2.1 Pipeline route and turning points (TPs) along the pipeline route shall be located by the
SURVEYOR in consultation with Company/Engineer-in-charge considering the following:
To avoid obstructions along the line, by ranging on ground and shifting the Turning
Points if need be.
Terrain gradient to be checked by using hand held inclinometer.
Ensure proper angle of crossing by keeping as nearly right angle (to road/ canals
(lined/unlined)/ rail/ rivers/ streams, etc.) as possible. The right angle may be laid on
ground by using a chain or string lengths in ratio of 3, 4 and 5.
To check from construction point of view and avoid objects like power, telephone and
telegraph poles, walls, tube wells or such other structures falling in the strip of land,
30m on either side of pipeline alignment.
e. To maintain minimum distance of 100m between two consecutive turning points.
2.2 Staking of pipeline route
2.2.1 The pipeline defining trench centre line shall be staked by placing suitably painted marker
stakes at Turning Points (TPs) and at Intermediate Points (IPs) between consecutive TPs. All
Turning Points (TPs) and intermediate points are referred as Intersection Points.
The pipeline centre line shall be staked on the ground as follows:
First, the Turning Points (TPs) shall be staked on the ground. After locating and marking the
TPs, the intermediate points shall be staked while measuring slack distance. The staking shall
normally be done at intervals of 500 m along the centre line of the pipeline

sanitzleg e ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
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e-nmrsidP'"1 (A Gov' of !pima Undenaking) Page 11 of 24
2.2.2 The Intersection Points shall be serially numbered form the starting point. The serial number
of each Intersection Point shall be boldly inscribed on the marker stake. In addition, the
Turning Point (TP) marker stake shall identify the Turning Point reference number from the
starting point.
2.2.3 For Intermediate Points (IPs) letter "P" shall precede the serial number of the intersection
Point marker. For Turning Points, the letters "TP" shall precede the Turning Point reference
number, and the letter "P" shall precede the serial number of the Intersection Point.
2.2.4 The marker stakes at Turning Points (TPs) shall be referred with three reference stakes around
the TP. The reference stakes shall carry the Turning Point reference number and their
respective distance from the TP marker stake. •
2.2.5 Change in direction of line shall be marked on the TP marker stakes. In addition, direction
markers near TPs and other locations shall be placed wherever necessary.
2.3 Stakes and Markers
2.3.1 All marker stakes shall be pre-cast reinforced concrete blocks having dimensions 150 x 200 x
800 mm, and shall be buried to a depth of 500 mm. Stone pillars of similar dimensions can be
used in place of concrete blocks.
The exposed surface of the blocks shall have a smooth finish and shall be painted with 'Post
Office' red paint. All letters and figures shall be paint marked on the surface of the blocks in
white.
2.3.2 On the top surface of the marker stake, a cross inside a circle shall be engraved at the centre or
a nail shall be put centrally inside an engraved circle, to indicate the exact position of the
Intersection Point. The circle shall be of approximately 50 mm diameter.
2.3.3 SURVEYOR can, however, propose to the Company/ENGINEER-IN-CHARGE other types

of stakes/markers which are better suited to site conditions.
2.4 Bench Marks
2.4.1 Permanent Bench Marks (BM) approx. every 5 km or permanent structures on or off the
Right-of-Use (ROU) shall be established and described. Bench marks shall be located in such
a manner that they will not be destroyed when the ROU is cleared for construction.
2.4.2 Additional permanent bench marks shall be established near the major pipeline crossing sites.
2.4.3 Location of Bench Marks shall be established in the field by using reinforced concrete/stone
blocks similar to pipeline marker stakes described in clause 2.3.1 of this specification. Exact
position of BM shall be marked by a cross inside a circle or a nail put centrally inside an
engraved circle on the top surface of the concrete block. The reduced level of the BM shall be
paint marked on the concrete block. Letters "BM" shall precede the reduced level of bench
mark recorded to the second place of decimal.
2.4.4 Accuracy of the reduced levels of the Bench Marks shall be verified wherever possible by
checking levels with the nearest permanent Bench Mark established by Survey of India.

2.5 Crossings
2.5.1 General
As far as possible, crossings shall be made at right angles. The SURVEYOR shall record the
angles of crossing for all fences, property lines, utilities, roads, railways, canals, streams, etc.
that are crossed. In addition, the true bearings of the centreline of the road, railway, canal, as
well as that of the pipe centre-line shall be recorded. Turning Points (TPs) provided on either
side of crossings shall be located, minimum 50m from the crossing's boundaries, in stable and
firm ground.
2.5.2 Railway Crossings
The angles for all railway crossings shall be as close to 90 degrees as possible, but in no case
less than 85 degrees to the centre-line of the railway.
2.5.3 Primary Road Crossings
Primary roads are the National & State Highways, all-weather roads (paved/unpaved) and
roads providing access to major installations. The angle of crossings shall be as close to 90
degrees as possible, but in no case less than 80 degrees to the centre line of the road.
2.5.4 Secondary Road Crossings
The angles of crossing for secondary roads shall be as close to 90 degrees as possible, but in
no case less than 45 degrees to the centre-line of the roads. All seasonal roads, unpaved
village roads, cart-tracks, etc. come under this category.
2.5.5 River Crossings
These crossings shall be established as close as possible to the locations shown on the route
map. Crossings shall be located in a comparatively straight reach of the river where the banks
are stable and there is sufficient area for construction. Angle of crossing shall be as close to 90
degrees as possible.
2.5.6 Canals (lined/unlined) /Drainage/Stream/Nala/Ditch Crossings
The angle of crossing shall be as close to 90 degrees as possible but in no case less than 60
degrees to the centre-line of the canal/drainage/Stream/ Nala/ditch. Crossings shall be located
where there is no evidence of slumping or erosion of banks, or bed.
2.5.7 Utility Crossings
Utilities crossed shall be located at their centrelines with stakes containing station numbers in
the survey. The angle of crossings shall be measured and locations established relative to their
above ground facilities. The names and sizes of all utility lines shall be included in the survey
notes. In cases of overhead power and telephone lines, the distance to the poles and towers on
each side of the survey line shall be measured, and the numbers of poles or towers noted. Line
voltage shall also be recorded. Where possible, the survey shall be established so that there is
a minimum distance of 50 metres from the survey line to the nearest High Tension (11KV, 33
KV and above) pole or tower.
Underground utilities shall be located as far as possible and staked for a minimum distance of
30 metres on each side of the survey line.

ligklea ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
51g7 ttlaiegNiffi ILIA LIMITED (ONSHORE)
A GoA al Inas Unaerlaknal Page 13 of 24
2.6 Built-up Areas
2.6.1 Monuments and Properties
The pipeline alignment shall run clear of the existing monuments, properties and structures
etc., as indicated in Pipeline Route Survey Data Sheet (Refer Annexure-I for sample).
For congested areas, closer distance may be adopted; however, location shall be approved by
Company/Engineer-in-charge
2.6.2 Parallel Alignment
The pipeline alignment wherever runs parallel to an existing or planned under/over ground
facility will be treated as parallel alignment. For underground facilities SURVEYOR shall
identify and locate them with suitable pipe locator/ cable locator. The following clearances
shall be observed in case of parallel alignment defined above unless specified otherwise:
Between existing/planned electrical power cables/lines and the proposed pipeline - 50.0
metres
Between existing/planned communication cables/lines and the proposed pipeline - 25.0

metres
c. Between existing/ planned pipeline and the proposed pipeline — 50.0 metres
2.6.3 Parallel Encroachment
Unless otherwise stated, when the pipeline alignment runs generally parallel to a road or
railway it shall be kept sufficiently clear of the Right of Way limits of the facility.
2.7 Accuracies in Measurement
2.7.1 SURVEYOR shall incorporate corrections to the linear ground measurement due to standard
errors (and variations from standard temperature and/or pull in case of chain survey, wherever
specifically approved by Company).
2.7.2 The error for angular closure for the work shall not exceed one minute per station and for
linear measurements it shall be read to the nearest 0.001 m.
2.7.3 The error on closure for measurements on vertical distance to establish bench marks shall not
be more that 244K millimetres (where 'IC' is the linear distance in km). The observations for
measurement of vertical distances on bench marks shall be read to accuracy to the nearest 5
mm and for Intersection Points and other points along the pipeline route and at crossings to the
nearest 10 mm. The error of misclosure in vertical distance shall be distributed linearly.
2.7.4 Azimuth control shall be maintained by observations of the Sun or Polaris at intervals of 15-
20 km by closing the traverse on existing control points. These observations of bearings
together with deflection angles shall be recorded in survey notes.
Azimuth misclosure based on bearings with observed angles at Turning Points shall be equally
distributed over the number of stations observed in between. Accuracy of azimuth
observations shall be acceptable if the three deductions agree within one minute when Sun is
used for Azimuth observation. Incase of stars/Polaris observation, computed values should
agree within 10 to 15 secs.
This check is not mandatory when using DGPS system for establishing location/co-ordinates.

$5iifaeleit ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
Elffleg w INDIA LJMITED
2.8 Chainage
2.8.1 Distance measurement shall be made by Electronic Distance Measurement (EDM) equipment
(or by using 50 m steel tape or 30 m chain if specifically approved by the Company).
However, in case of abrupt slope change the tape/chain shall be used and it shall be
straightened parallel to the probable grading.
2.8.2 Distance between Intersection Points staked along the pipeline route should be measured and
recorded. In addition, distance between level points shall also be measured and recorded.
2.8.3 Chaining, wherever permitted, shall be continuous in the direction of survey.
2.8.4 The true bearing of all straights shall be observed and recorded.
2.8.5 Data on nature of terrain, viz. sandy, stony, vegetation, etc. and type of ground will also be
recorded along with chainages of change points.
2.8.6 Check on distance measurements shall be by Stadia method at the time of levelling.
2.8.7 Standard survey formats shall be used for record keeping.
2.9 Measurement of Horizontal Angles
2.9.1 Horizontal angles are measured to indicate the change in direction of alignment and specify
the horizontal bend at the Turning Points.
2.9.2 Theodolite, reading direct to 10 seconds or better, shall preferably be used. Angles shall be
measured clockwise from back station to fore-station. Mean of two readings-one on face left
and other on face right shall be taken as the horizontal angle.
2.9.3 The line at both ends shall be tied to the grid control system being used for end facilities. True
bearing at the beginning, end and at every 15-20 km shall be observed to keep a check on
errors in angular measurements.
2.10 Profile
2.10.1 Continuous profile of the proposed pipeline route shall be established from the reduced levels
taken.
at the starting point,
at all Turning Points (TPs),
at all Intermediate Points staked on the ground,
at all points on the pipeline route where there is a change in slope.
2.10.2 When the terrain is flat, reduced level shall be additionally recorded along the pipeline route at
100 m interval.
2.10.3 When the terrain is undulating, observation of reduced level shall be made at a sufficient
number of points so as to give an accurate plotting of the ground profile along the route.
2.10.4 For road and railway crossings, the reduced levels shall be recorded at interval of 5 m along
the pipeline alignment and at closure intervals wherever there is a change in slope within the
entire width of the Right-of-Use of the road/railway.

ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
$ig:ar Mews" INDIA LIMITED
in poi amcu underutngi (ONSHORE) Page 15 of 24
2.10.5 For river/stream/nala/canal crossings, levels shall be taken at intervals of 5 m up to 30 m

beyond the highest banks on both sides. Levels shall be taken at closer intervals, if there is a
change in slope.
2.10.6 In right-of-use having slope across the pipeline alignment, as encountered in hilly areas, Ghat
regions, ravines and other similar areas as directed by Company, cross-sections at 50 m
interval and for a length of 30 m on either side of the pipeline alignment shall be observed and
recorded
2.10.7 For major water crossing sites, cross section as above shall be observed at both banks.
2.10.8 Method of RISE and FALL shall be used to compute reduced levels of various points. Check
on computation shall be made by using the following formula:
Back site - Fore Site = :Rise = First R.L. - Last R.L.
2.10.9 Maximum misclosure shall not exceed 24'dK mm where IC' is the distance in km. Maximum
length of line of sight shall not exceed 100 m.
2.10.10 All levels shall be with respect to Mean Sea Level (MSL).
2.11 Co-ordinates and Grid
2.11.1 Differential Global Positioning System (DGPS) shall be used to determine co-ordinates of all
intersection points and facilities along pipeline route. Accuracy of co-ordinates shall be within
0.5 metre. Non-differential or autonomous GPS are not acceptable.
The following information shall be submitted for DGPS proposed by Surveyor for Company
approval:
GPS Receiver Model used :

Differential Receiver Type :
Guaranteed accuracy in metres :
SURVEYOR shall submit a procedure for setting up & use of DGPS. All co-ordinates shall be
indicated in UTM grid as well as geographic grid. In case more than one survey party is
deployed, each party shall use same reference grid and DGPS system.
2.12 Levels and Contours
2.12.1 In addition to the elevation along center line of route, the SURVEYOR shall obtain, using
Total Station, levels within 30 m wide corridor on either side of route alignment. Co-ordinates
(in UTM grid) of each level point shall also be recorded.
2.12.2 All such level points shall be plotted in the planimetry portion of the alignment sheets. The
levels shall be taken in such a manner that contour can be drawn with a contour interval of 5
m. SURVEYOR shall draw the contours from the data collected.
2.12.3 Electronic data shall be made available in a format compatible with commercially available
Digital Terrain Modelling (DTM) software.
2.13 Seismic Fault lines
2.13.1 Surveyor shall identify the type, chainage and locations seismic fault lines crossings. All the
fault lines within one kilometre on either side of pipeline alignment shall be indicated.

051PZIete ENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
Zigt16i1g1tlil
0 a UMITED
(ONSHORE)
(A Govt of India U ndel amn) Page 16 of 24
Surveyor shall also indicate fault lines are active / non active. In case of parallel fault lines, the
extent of length and distance from the pipeline alignment shall be furnished.
3.0 Presentation of Survey Data
The data collected during survey shall be presented in the form of drawing and document
listed below:
3.1 Drawings
3.1.1 As a minimum following drawings shall be prepared and submitted
S. No. Description Scale

Detailed Route Map 1:50,000
Additional Route Map 1:15,000
(for Hilly, Ghat and ravinous regions)
Alignment sheets covering
- Right-of-Use Planimetry in UTM grid 1:2500 along the line
1:2500 across the line
- Ground Profile 1:2500 Horizontal

1:250 Vertical
Crossing Details 1:100 Horizontal
(Road/Railway/Stream/Nala/Canal/Crossings) 1:100 Vertical
& Utility Crossings
Crossing details (River Crossings)
- Up to 250 m width 1:200 Horizontal
1:200 Vertical
- 250 to 500 m width 1:500 Horizontal

1:500 Vertical
- Greater then 500 m width 1:1000 Horizontal

1:1000 Vertical
Cross Section for sloping Right-of-Use 1:100 Horizontal
1:100 Vertical
Note: Crossing drawings shall be prepared using same horizontal and vertical scales as
indicated above. In case one crossing can not be accommodated in single sheet
additional sheets may be used. Not to scale (NTS) drawings shall be rejected.
3.1.2 Pipeline route map shall show all features including, but not limited to roads and railroads,
canals, streams, lakes, rivers, villages, towns, and cities that are located within a distance of 5
km from the pipeline centre-line on either side of it. For the entire region, contours shall be
plotted on the route map at 20 m contour interval. Additional information like cultivated areas,
barren land, areas prone to flooding, rocky areas and forests including access paths/roads to
Right-of-Use shall also be shown on the route maps.
Additionally for areas which are undulating such as hilly areas, Ghat regions, ravines, and
other areas as directed by Company, Pipeline route map to a scale 1:15,000 shall be drawn
over a distance of 1.0 km from the pipeline centre-line on either side of it. For such areas,
contours shall be plotted at 10 m contour interval.
3.1.3 Right-of-Use Planimetry drawings shall show all objects within 30 metres on either side of the
Pipeline in Plan and shall show spot level & contours at 5m interval.

1511WPRISENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
a megweINDIA LIMITED
ennt of India Undell*.^91 (ONSHORE) Page 17 of 24
3.1.4 For all rail, road, river, stream, canal and utility crossings, the angle of crossing shall be
mentioned.
3.1.5 For rail, road, river, stream and canal crossings wider than 10 m, the distances at the start and
at the end of the crossing from the nearest IP shall also be mentioned. For crossings less than
10 m, the distance of the centre line of crossing from the nearest IP shall be given.
3.1.6 For all river, stream and nala crossings, the level of water at the time of survey, High flood
level recorded in last 100 years and the approximate surface velocity of the flowing stream
(observed & recorded during survey) shall be reported in the survey drawings. Also, the
general nature of the surface soil (soft/hard, normal soil or rock/boulders) at the bed and banks
of the river/stream/nala shall be observed and mentioned in the drawings.
Ground profile (chainage v/s ground elevation) for the entire pipeline route shall be prepared
and presented in a tabular format using Microsoft Access Database format.
3.2 Documents
In addition to the drawings listed above, the SURVEYOR shall submit a report giving,
Details of survey methodology followed
Details of equipments used
Brief Route Description
Salient features of the route such as
Total length of pipeline
State wise distribution of pipeline route
Terrain details and land use pattern summary
No. of crossings (state wise & chainage wise)
Details of River crossings
State wise extent of forest/reserve forest/environmentally sensitive area
Significant elevation changes along the pipeline route with chainages
Nature of soil (sandy, clay, rocky(hard/weathered), marshy, etc.)
Location of Seismic Fault lines along the pipeline route
Print out of information required to be submitted as data base including
Level & contour information for DTM
Pipeline Profile data
TP detail

ENGINEERS FOR PIPELINE SURVEYS
azir EfiRegveli, LIMITED 6-71-0071 Rev. 3
lann eWremin) (A Gov/ al India Undetliongl (ONSHORE) Pape 18 of 24
APPENDIX-C
SOIL INVESTIGATION SURVEY ALONG PIPELINE
1.0 Objective
The objective of soil investigation survey is to obtain visual engineering classification of soil
and geotechnical properties of soil for design & engineering of various facilities required
along the pipeline route.
2.0 Requirements
2.1 General
2.1.1 The soil investigation includes boring, collection of disturbed samples from bare holes and
visual engineering classification of soil along the pipeline route, carrying out Standard
Penetration Test (SPT) at specified locations and getting the soil sample collected, from such
bore holes, tested at laboratory for specified engineering properties and submission of detailed
report to Company.
2.1.2 Visual classification of soil shall be in accordance with IS-1498; "IS Classification and
Identification of Soils for General Engineering Purposes". Geotechnical investigation of soil
shall be carried out as per relevant clauses of IS 1892 and other applicable IS standards.
2.2 Location of Bore Holes
2.2.1 Boreholes shall be made at an interval of 250 m along the pipeline route, at all intermediate
points where there is apparently a change in the type of soil and at other places as given below
by Company/Engineer-in-charge.
2.2.2 For canal, stream and river crossings, boreholes shall be made one on either bank and one on
the bed of water crossing. For railroads, state highways and national highways, at least one
bore hole shall be made at each crossing location.
2.2.3 Boring shall be carried out in accordance with the provision of IS: 1892. Minimum diameter
of boring shall be 150mm. Auger boring shall be resorted to above water table, whereas below
water table the boreholes shall be advanced by rotary drilling with mud circulation through all
kinds of soil other then rock. While boring above water table, no water shall be introduced in
boreholes. Casing shall be used to support the sides of boreholes in soft to firm soil.
224 Except for crossing location as defined under clause 2.2.5, the boring shall be either
terminated at a depth of 3 m below NGL or on top of bed rock if rock is encountered at a
depth of less than 3 m.
2.2.5 In case of boring at Highways (National/ State), River and Railways crossings, the boring
shall either be terminated at a depth of 5 m below NGL or on top of bed rock, if rock is
encountered at a depth less than 5 m.
2.2.6 Additionally, bore holes shall be made at all SV stations, IP stations and at all terminal
locations.
3.1 Results of soil investigation survey and laboratory test carried out shall be submitted in the
form of report covering as a minimum the following.

Ifg-ez 'Were INDIA LJMITED

eh
ri r ENGINEERS FOR PIPELINE SURVEYS
(ONSHORE)
6-71-0071 Rev. 3
Page 19 of 24
Visual engineering classification of soils encountered along the pipeline route in

borelog form. Depth of Ground Water Table (GWT) below NGL shall also be
mentioned if encountered.
Soil profiles along the pipeline route shall also be prepared and attached with the
report.
Regions along the pipeline route where hard rock is present and special excavation
techniques like blasting, etc. needs to be adopted for excavation of pipeline trench
shall be clearly indicated in the report.
Summary of results obtained from various laboratory tests and their interpretation to
evaluate various soil parameters.
3.2 Visual engineering classification of soils obtained from bore holes shall be shown in
Alignment sheets also, whenever preparations of alignment sheets are included in
SURVEYOR's scope of work.
3.3 Additionally, the undisturbed samples shall be collected (150 mm 0 bore hole up to a depth of
5.0m from NGL) as per clause no. 2.2.5 above, i.e. at location of seismic fault line and one
each at 500m on either side of fault line crossing. The samples shall be laboratory tested for
the following:
Natural Moisture Content
Bulk and Dry density
Grain Size Analysis
Tri-axial shear (unconfined un-drained) test for clayey soil
e. Box shear test for granular soil
With the above tests the following soil data along the route shall be generated:
Type of soil (sand, silt, clay, etc.) up to a depth of 5.0 m
Bulk and dry density of soil
Maximum level of water table
Angle of internal friction (0)
e. Un-drained shear strength in case of clayey soil (c)

APPENDIX-D
LOCATION CLASS SURVEY
ADDITIONAL REQUIREMENTS FOR GAS PIPELINES
DETERMINATION OF LOCATION CLASS FOR DESIGN AND CONSTRUCTION
1.0 When survey is performed for gas pipelines, the class locations based as per code ANSI B
31.8 "Gas Transmission and Distribution Piping Systems" shall be recorded along with
chainages at change points of each class location.
2.0 Location classes along the pipeline route shall be determined as follows:
A zone, 400m wide (one quarter mile), shall be considered along the pipeline route with the
pipeline in the centre-line of this zone. Then the entire route of the pipeline shall be divided
into lengths of 1600m (one mile) such that the individual lengths will include the maximum
number of dwellings intended for human occupancy. The number of such dwellings which are
intended of human occupancy within each 1600m (one mile) zone shall be counted and
reported along with other survey data.
3.0 Areas shall be classified based on guidelines as given below:
3.1 a) Class 1 Location
A Class 1 Location is any 1600m (one mile) section that has 10 or fewer dwellings
intended for human occupancy.
Class 2 Location
A Class 2 Location is any 1600m (one mile) section that has more than 10 but less
than 46 dwellings intended for human occupancy.
Class 3 Location
A Class 3 Location is any 1600m (one mile) section that has 46 or more dwellings
intended for human occupancy except when a Class 4 Location prevails.
d) Class 4 Location
A Class 4 Location includes areas where multi-storey buildings are prevalent, and
where traffic is heavy or dense and where there may be numerous other utilities
underground.
3.2 In addition to the criteria contained in Clause 3.1, while classifying areas, additional
consideration must be give to possibilities of increase in concentration of population along the
pipeline route such as may be caused by the presence of schools, hospitals, recreational areas
of an organized character, places of assembly, places of worship etc. If one or more of these
facilities are present, the area shall be classified as a Class 3 Location.
3.3 Notwithstanding the provisions of Clause 3.1 and 3.2 above, while determining Class
Location of an area, due consideration shall be given to the possibility of future development
of the area during the design life of the pipeline. If it appears likely that future development
may cause a change in the Location Class, this shall be taken into consideration while
determining its Class Location.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell — All rights reserved

APPENDIX-E
CADASTRAL SURVEY
1.0 Objective
The objective of cadastral survey is to identify the ownership & land use details and collect
data /all other details sufficient for acquisition of RoU, under the Petroleum and Mineral
Pipelines (Acquisition of Right of User in land) Act 1962 of Government of India and its
amendments, along the pipeline route identified by Company and duly surveyed and
established on ground.
2.0 Requirements
2.1 The SURVEYOR shall be responsible for collecting all revenue and other maps as well as
arranging all necessary forms required for carrying out cadastral survey at his own cost.
Company will assist the SURVEYOR by way of issue authorization letter only. Alignment of
established pipeline route will also be made available to SURVEYOR.
2.2 SURVEYOR shall carry out plane table survey, as may be required, along the pipeline route
covering an area 30 m on either side of centreline to show the following details in cadastral
maps to be prepared on 1:2500 scale.
Pipeline alignment as per details made available.
RoU limit on either side of centreline as per details given in Data Sheet. RoU limit at
turning points shall be marked in a curve having turning radius of 50 times pipe line
outside diameter for pipeline size 18" & above. The pipeline diameter shall be
indicated in data sheet. In case of multiple lines in same RoU, the largest pipe size
shall be considered for this requirement.
Property identification/survey number, Part "Hissas" on survey numbers as per the

latest official revenue records.
Identification of RoU of existing pipelines/utilities/ rail, roads, canal, river and other
pipeline crossings on the Cadastral maps.
Number and type of trees within RoU limits.
Other major features such as given below:
All built up areas.
Religious places, schools, dharamshala, hospitals etc.
Railway lines, National/State Highways and district / village and

Panchayat roads.
Creeks, rivers, canals, drains etc.
Forest land (Reserved/Protected/Social)
Wildlife sanctuaries
Industrial Land.

Quary/mining and other prohibited areas.
Over-head/underground utility crossings
The above information shall be adequate in all respect for RoU acquisition and obtaining
forest clearance (if any).
2.3 Arrange for and furnish VII and XII extracts in duplicate of all land areas covered/ shown in
cadastral map as per clause 2.2 above. The extracts are required to be duly certified by the
local concerned authorities. Expenses in obtaining these extracts shall be borne by the
SURVEYOR.
2.4 In respect of the map at 2.2 above, marking of part "Hissas" as per the latest revenue records
shall be checked/ verified by the local concerned authorities. SURVEYOR shall ensure that
the land records are submitted to Company for checking and verifications as work proceeds.
2.5 SURVEYOR shall also prepare a schedule, as per format to be approved by Company/
Engineer-In-Charge, showing information on part "Hissas" and details of ownership (to be
extracted from map at para 2.2 above for obtaining pipeline Right of Use (ROU).
2.6 SURVEYOR shall prepare a summary of ownership details of land covered within 30 m on
either side from the centreline of pipeline giving all relevant details village wise including
land cost and crop cost supported by the relevant documents from respective Tehsil/ District
head quarters.
2.7 SURVEYOR shall furnish requisite Performa (number of copies as specified in the
CONTRACT) duly completed on proper schedule form, including of procurement of all
revenue maps and forms required from revenue department, submitting all proposal village
wise and Tehsil vise.
The SURVEYOR shall submit all survey data in the form of following drawings /documents:
3.1 Cadastral maps in scale 1:2500 as per clause 2.2 above.
3.2 Cadastral Survey Report including summary of ownership details, land and crop cost detail
and other documents as per clause 2.5 & 2.6 as above.
3.3 All revenue maps collected by the SURVEYOR from various authorities
3.4 All forms/performas necessary for estimation of land cost.
3.5 Any other detail as specified by Company.

a-at-mitaENGINEERS FOR PIPELINE SURVEYS 6-71-0071 Rev. 3
lig arraweger INDIA UMITED
ANNEX1LTRE-I
PIPELINE ROUTE SURVEY DATASHEET
Gradient (RoU) 1:5 (max.) Along pipeline alignment (see note-5)
1:10 (max.) Across pipeline alignment
Bend Radius 30 D for pipeline size up to 16"
40 D for pipeline size greater then 16"
(D= Out side diameter of pipeline)
Minimum Distance between TP's 100 m
Maximum Deflection Angle at TP 90°
RoU width 20 m (5 m in left and 15 m in right side of pipeline

centreline while viewing in the direction of flow)
unless specified otherwise.
Minimum distance
from existing Habited dwellings 15 m
from Buildings/structures/monuments : 50 m
Co-ordinates of starting point To be filled by Survey Contractor
Notes:
Number of TP's along the pipeline route shall be kept to a minimum. Additional traversing
required for TP optimization shall be carried out by the Contractor prior to finalisation of TPS.
Chainages for pipeline shall start with 0.0 chainage in the direction of flow.
At road/rail/canal crossing locations, nearest TP on either side shall be located at a distance

not less than 50 m from the RoU of the facility being crossed, unless instructed otherwise by
Company Representative.
In case of major river crossings, no TP shall be located within 150 m from the defined bank on
either side, unless instructed otherwise by Company Representative.
5. Slope up to 1:5 can also be acceptable for hill section.

OW:Ate ENGINEERS FOR PIPELINE SURVEYS
ItgarEVIegl
e INDIA LIMITED 6-71-0071 Rev. 3
(A GoN a A is undertsung) (ONSHORE) Page 24 of 24
ANNEXURE-II
SAMPLE FORMATS
SURVEYOR shall prepare all drawings as per the enclosed formats. Soft copies of formats will be
provided at appropriate time.
Alignment Sheets
Pipeline Route Maps*
River Crossings
Nala/CanaUOther water body Crossings
Railway Crossings
Road Crossings
*Pipeline route maps shall be furnished in ".KML & KMZ" file also.

tg
I
151fRiseA ENGINEERS FOR POSITIVE MATERIAL
si at efaleg INI NA LIMITED
/A “nul na. Lnden.,), IDENTIFICATION (PMI) AT
6 - 81 - 0001 Rev. 2
SUPPLIER'S WORKS Page I of 8
covingii 4
c 1T
,flcomoict) TIPTth LI 111

f'6g itta-vr
FOR
POSITIVE MATERIAL
IDENTIFICATION
(PMI)
AT SUPPLIER'S WORKS
40D ., 15,
2 20.10.11 REVISED AND RE-ISSUED AKC DM
1 15.07.08 REVISED AND RE-ISSUED

NKR SSL SKP VC
0 07.12.00 ISSUED AS STANDARD SPECIFICATION AKC AKB AKB MI
Standards Standards
No Date Purpose
by by Convenor Chairman
Approved by
Formal No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

151Mae? - le.' ENGINEERS FOR POSITIVE MATERIAL
imegver INDIA LIMITED
yin eRaWanJelwill Govl of India Undertakno IDENTIFICATION (PM I) AT
6-81-0001 Rev. 2
SUPPLIER'S WORKS Page 2 of 8
Abbreviations:

AS Alloy Steel
LSTK Lump Sum Turn Key
PMI Positive Material Identification
Sch Schedule
SS Stainless Steel
TPI or TPIA Third Party Inspection Agency
Inspection Standards Committee
Convenor: Mr.AK Chaudhary
Members: Mr. SS Lotay

Mr. SC Gupta
Mr. RK Singh
Mr. Rajeev Kumar
Mr. Anoop Goel
Mr. G Suresh
Mr. G Poornachandra Rao
Mr. MP Jain (Projects)

151M4-e?fte ENGINEERS FOR POSITIVE MATERIAL
Ogrir tfigtegW INDIA LIMITED
Gorl of India undertaking} IDENTIFICATION (PMI) AT
6-81-0001 Rev. 2
CONTENTS
1.0 SCOPE 4
3.0 DEFINITIONS 4
4.0 PMI EXAMINATION 5
5.0 ACCEPTABLE METHODS FOR PMI 5
6.0 EXTENT OF PMI EXAMINATION 6
7.0 RECORDING AND DOCUMENTATION 7
8.0 MARKING 7

ft/ ENCJNEERS FOR POSITIVE MATERIAL
beire,altateg ‘60
'- -1 INDIA LIMITED 6-81-0001 Rev. 2
IDENTIFICATION (PMT) AT
1.0 SCOPE
1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at the Supplier's works on Metallic Materials procured either directly by the
Owner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.
1.2 Any post order deviation from this specification must be approved by Owner/EIL in the
Deviation/ Waiver Permit format (No. 5-0000-0180-F1) enclosed with Material Requisition.
1.3 This specification covers the procedures and methodology to be adopted to assure that the
chemical composition of the material is consistent with the material specifications as specified
in purchase documents using 'Alloy Analyzer' at the time of final inspection before dispatch.
1.4 The scope of this specification shall include but shall not be limited to Positive Material
Identification (PMI) to be performed on Materials listed below:
1.4.1 For alloy Steel materials as below:

Alloy Steel Pipes including Clad Pipes
Alloy Steel Flanges & Forgings
Alloy Steel Fittings including Clad Fittings
Alloy Steel Fasteners
Alloy Cast & Forged steel valves
Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)
Longitudinal Pipe & Fittings Welds.
Gaskets (for Ring Type Joints)
1.4.2 For Carbon Steel materials as below:

All Carbon Steel Piping items under NACE or HIC or H2
Carbon Steel flanges and valves (Rating 900# and above)
Carbon Steel Pipes & fittings for following thicknesses:
Size 1"- 2" NB : Sch 160 & above
Size 3" NB : Sch XS & above
Size 4" - 12" NB : Sch 120 & above
Following items shall be excluded from scope of PMI examination.
Gaskets other than for Ring Type Joints

Internal Components of Valves
1.5 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In
case of any defective materials being found at site, the Supplier shall be responsible to effect
replacement of such defective materials at project site without any delays to the satisfaction of
EIL site RCM (Resident Construction Manager).
2.1 API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program for
New and Existing Alloy Piping Systems.
3.0 DEFINITIONS
3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referred
items. This definition shall also include any sub-Supplier or manufacturer on whom a sub-order
is placed by the Supplier.

SaIRCIELM—; ENGINEERS FOR POSITIVE MATERIAL
Par taiReZ VW INDIA LIMITED 6-81-0001 Rev. 2
IDENTIFICATION (PM I) AT
3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat and
Heat treatment lot.
3.3 Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionally
added to enhance mechanical or physical properties and/or corrosion resistance.
4.0 PMI EXAMINATION
4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of this
Specification Approval of PMI Procedure shall be obtained from Owner/EIL/TPIA prior to
commencing manufacture/ inspection of product.
4.2 PMI examination of materials is independent of any certification, markings or colour coding
that may exist and is aimed at verifying that the alloy used are as per specified grades.
4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to
cutting to ensure maintenance of identification on off-cuts.
4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or alloy
material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from
ferro-magnetic materials.
4.5 PMI examination is subject to surveillance inspection by Owner/EIL/TPIA.
5.0 ACCEPTABLE METHODS FOR PMI
5.1 The method used for PMI examination shall provide a quantitative determination of the alloying
elements like chromium, nickel, molybdenum or vanadium in Alloy Steel items.
5.2 Instruments or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of alloying elements
present.
5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or
"Optical Emission" type each capable of verifying the percentage of alloy elements within
specified range.
5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.
5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the
specified range.
5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources etc., and the data of the last service shall be stated on
the PMI Report Form (Sample enclosed).
5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginning
and end of each shift. Instrument must be checked against known standard for each alloy type
to be inspected during the shift.

ISillaZreq e ENGINEERS FOR POSITIVE MATERIAL
s'Ig7e2eg W
INDIA UMITED
Govt a Inaa Undenakingi IDENTIFICATION (PMI) AT
6-81-0001 Rev. 2
5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use as
a random spot check on the instrument calibration.
5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or
abrasive paper. No permanent marks, which are injurious to the usage of product in service, are
acceptable.
5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence
instrument.
5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer
being used. Modification of these procedures if any must be approved by Owner/EIL.
5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may
perform the examination. Otherwise PMI examination shall be sub-contracted to an independent
testing agency approved by EIL.
5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejection
note shall be issued.
6.0 EXTENT OF PMI EXAMINATION
Following sampling plans shall be applicable for PMI examination of various items.
Flanges, Fittings 100%

Valves, RTJ Gaskets
Pipes 100% (for pipes procured from traders).
2 random samples drawn from each

Size/Heat/Lot (for pipes procured directly from mills)
C. Fasteners
Lot Size Sample Size
Upto 100 2% (Min 2)

101 to 500 1% (Min 3)
501 and above 0.5% (Min 5)
Note:
For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as
weldments.
Whenever any sample drawn to PMI test on the basis of percentage selection in B & C
above, fails to meet specification requirements, 100% of items of lot shall be tested for
PMI.

i.311-aelti . ENGINEERS FOR POSITIVE MATERIAL
ogrir EiRtegi INDIA LIMITED
IA Go' at India Undertaking) IDENTIFICATION (PMI) AT
6-81-0001 Rev. 2
7.0 RECORDING AND DOCUMENTATION
The results of PMI examination shall be recorded in a Report Format as enclosed with this
specification.
8.0 MARKING
8.1 All alloy materials tested by PMI shall be identified using either of the following methods by
indicating "PMI OK"
Bar Code/Hologram Sticker

A low stress stamp marking

012-ael ie ENGINEERS FOR POSITIVE MATERIAL
st",ar &Reg W INDIALIMTED 6-81-0001 Rev. 2
GOA Of India undertakng) IDENTIFICATION (PMI) AT
POSITIVE MATERIAL IDENTIFICATION REPORT Page of

BULK MATERIALS
Project: Client Job No.
PMI Report No. Supplier/Sub-Supplier
Purchase Order No. Testing Agency
Purchase PMI Location

Requisition No:
Bulk Item Type (as per Requisition)
Material Specification/Grade
Number of items in Lot
Requisition Item No./ Description Major content, Weight Percent Remarks

Accept/Reject
Element Cr Mo Ni V
Specified Range
Actual observations
Instrument Type / ID
Last Service Date Witnessed By

Inspection Agency

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STANDARD FOR SPACERS STANDARD No.
OfitzleiglikEtgaNEERS AND BLINDS 22" & ^. 26" 7-71-0030 Rev. 0
0:47 fl' :eNDIA UmiTED FOR PIPELINE JOBS
(A Gail of info Undeflalong)
(150#, 300# AND 600# FF) Page 1 of 3
E d0 Dia. Hole Welded lifting

13mm0 Hole for Spacer plate
Welded
lifting plate -o
Dia., rating &

6mm(Typ) material to be
marked here.
Dia., rating &
material to be
marked here
0
ILI
. 1\ Two Nos
Two Nos A
Alignment
Alignment Guides
Guides BLIND
SPACER
NOTES:
Both surfaces shall have o resultant smooth finish of 125 AARH.
Dimensions are for flanges as per MSS SP 44 for 22" and ASME B 16.47A (MSS SP 44 )
for sizes 26" to 60"
Diameter, rating & material specification shall be marked on welded fixed plate.
Material of handle and alignment guide shall be same as spacer/blind..
Thickness 'A' is based on ASTM A 516 Gr.70 with corrosion allowance of 1.5mm
on each face.
5. Dim. D shall be calculated and matched with inside diameter of the mating flanges/pipe
for piggable lines.
6. Alignment Guides shall be welded in the middle of thickness of spacer and blind both.
150#
0 A B C D (Note 5) E F G d
30 641 450 545 35 15 327 20
22
35 749 510 646 35 15 384 20
26
37 800 539 695 33 15 412 20
28
39 857 567 746 30 15 438 20
30
42 914 605 795 30 15 466 20
32
44 965 631 846 42 15 492 20
34
47 1022 659 895 40 15 520 20
36
49 1073 945 48 15 552 20
38 694
51 1124 720 994 44 15 578 20
40
54 1194 748 1045 41 18 606 20
42
56 1245 777 1094 38 18 635 20
44
59 1295 802 1145 56 18 660 20
46
61 1359 831 1194 50 18 689 20
48
66 1461 888 1294 45 18 742 26
52
70 1575 948 1394 42 27 800 26
56
75 1676 1002 1492 48 27 854 26
60
±0.3 *0.5 Too ±0.5 ±0.5 ±1.0
TOL. ar. . . -... 2DM
21.08.12 ISSUED AS STANDARD S J
0 Stds. Committee Stds. Bureau
Prepared Checked Convenor Chairman
Rev. P urp os e by
No. Date by Approved by
STANDARD No.
STANDARD FOR SPACERS
aRziee ENGINEERS AND BLINDS 22" & .^-26" 7-71-0030 Rev. 0
falateu ve INDIA LIMITED
..,,xweAeem
FOR PIPELINE JOBS
G" of indo Uodertakin9)
(150#, 300# AND 600# FF) Page 2 of 3
die Die. Hole E

Welded lifting
13mm0 Hole for Spacer plate F
Welded
lifting plate
Dia., rating &

marked here.
Dia., rating & a.
material to be
marked here U
CD
x 0
ILI 1\ Two Nos
Two Nos A
Alignment
Alignment Guides
Guides BLIND
SPACER
NOTES:
Both surfaces shall have o resultant smooth finish of 125 AARH.
Dimensions are for flanges os per MSS SP 44 for 22" and ASME B 16.47A (MSS SP 44)
for sizes 26" to 60" .
on each face.
Dim. D shall be calculated and matched with inside diameter of the mating flanges/pipe
for piggable lines.
Alignment Guides shall be welded in the middle of thickness of spacer and blind both.
300#
A B C D Nee 5) E F G d
44 641 545 37 15 349 20
22 494
52 749 561 646 37 15 414 20

26
28 56 800 593 695 33 15 446 20
60 857 621 746 35 15 473 20
30
63 914 650 795 48 15 500 20
32
67 965 678 846 42 15 525 20
34
71 1022 710 895 54 18 555 20
36
74 1029 659 945 47 18 524 20
38
78 1086 694 994 41 18 554 20
40
82 1137 720 1045 54 18 579 26
42
86 1194 751 1094 47 27 606 26
44
90 1245 783 1145 61 27 633 26
46
93 1302 808 1194 53 27 658 26
48
101 1410 866 1294 42 35 711 26
52
108 1518 929 1394 76 40 768 32
56
116 1626 980 1492 71 40 819 36
60
TOL. ±0.3 ±0.5 +roo ±0.5 ±0.5 *1.0
S SKY DM
0 21.08.12 ISSUED AS STANDARD Stds. Bureau
Checked Stds. Committee
Prepared
Rev. Convenor Chairman
No. Date Purpose by by Approved by
STANDARD FOR SPACERS STANDARD No.
- ENGINEERS
Onazthak AND BLINDS 22 " & ?.- 26" 7-71-0030 Rev. 0
IgtirEPeuWINDIA LIMITED FOR PIPELINE JOBS
lanen ernwasSICI,A) IA Gov1 of Ind* Unclerlion9/
(150#, 300# AND 600# FF) Page 3 of 3
E d0 Dia. Hole E
Welded li ling
13mm0 Hole for Spacer plate
only F I F
Welded I I
lifting plate v
ul
-- —'
Mi
M
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v
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Guides I
SPACER BLIND
NOTES:
Both surfaces shall have a resultant smooth finish of 125 AARH.
Dimensions are for flanges as per MSS SP 44 for 22" and ASME B 16.47A (MSS SP 44)
for sizes 26" to 60"
on each face.
Dim. D shall be calculated and matched with inside diameter of the mating flanges/pipe
for piggable lines.
Alignment Guides shall be welded in the middle of thickness of spacer and blind both.
600#
A B C D (Note 5) E F G d
22 63 641 510 545 38 15 363 20
26 74 749 583 646 38 15 430 20
28 80 800 612 695 42 15 454 20
30 85 857 640 746 46 15 482 20
32 91 914 672 795 49 18 508 20
34 96 965 697 846 56 18 533 20
36 102 1022 732 895 56 18 562 20
38 107 1054 710 945 60 18 549 26
40 112 1111 735 994 49 27 574 26
42 118 1168 777 1045 67 27 606 26
44 123 1226 802 1094 54 27 631 26
46 129 1276 831 1145 60 35 660 32
48 134 1334 872 1194 60 35 692 32
52 145 1435 935 1294 65 40 746 32
56 156 1543 1002 1394 72 40 803 36
60 167 1657 1072 1492 102 40 863 36
TOL. ±0.3 ±0.5 +I N ±0.5 ±0.5 ±1.0
Oar)
"—VM DM
0 21.08.12 ISSUED AS STANDARD S SK
Stds. Committee Stds. Bureau
Prepared Checked Chairman
Rev. Convenor
Date Purpose by by
No. Approved by
STUD BOLTS RF 150# STANDARD No.
ENGINEERS
ogell faMeg
Weff elMaer01 3VWM
INDIA LIMITED
IA Govt of India Undertaking)
DIMENSIONS
(ASME 816.5)
7-44-0250 Rev. 5
Page 1 of 3
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4 31.07.2006 REAFFIRMED AND ISSUED AS STANDARD RN DM MRC VJN
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eiENGINEERS DIMENSIONS
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t31foil t ENGINEERS
51gai Elf5teg INDIA LIMITED DIMENSIONS 7-44-0250 Rev. 5
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5 25.07.2011 REVISED AND ISSUED AS STANDARDISH RN ATD DM

No. by by
Approved by
LOW SUPPORT SLIDING AND FIXED STANDARD No.
ENGINEERS
del8M
le soma
ONDIA UNITED
(A Cot of 444a Undorta/in)
FOR BARE AND INSULATED PIPE
SIZE 3/4" THRU. 1-1/2" TYPE - L15
7-44-0635 Rev. 4
Page 1 of 1
DETAIL-M
40
z
0 0
z U–BOLT TYPE–C4
FIG-2
°m (NOTE-1,2)
NOTE-4 (TYP)
WODM IN RT T
150x150x8 THK.
SLIDING PLATE
100x100x8 THK.
INSERT PLATE
K.
ARRANGEMENT TYPE-1 ARRANGEMENT TYPE-2

(SLIDING) (SLIDING)
PLAN
DETAIL-M (FOR TYPE-1&3)
40
z
Na U–BOLT TYPE–C4
FIG-2
Ii (NOTE-1,2)
Mk.
FIXFD PI ATE_ INSERT PLATE

100x100x8 THK. 150x 150x8 THK.
fig)! OWAT CI H 11 4x I K.
ARRANGEMENT TYPE-3 ARRANGEMENT TYPE-4

(FIXED) (FIXED)
a" = (FOR ARRANGEMENT TYPE 1 & 3)
D E
3/4" 36
1" 45
1 1/2" 60
NOTES:-
SYMBOL
NOM. PIPE NA
FOR DETAILS OF U—BOLT TYPE—C4 REFER DL STD. 7-44-0644.
ISA 125x75x8
NOTE – 3
U—BOLT MATERIAL SHALL BE EQUIVALENT TO THAT OF UNE—PIPE.
FOR DETAIL—M. FOR CARBON STEEL(CS) PIPE USE CS ANGLE BUT

—
IN CASE OF ALLOY—STEEL/STAINLESS STEEL USE BUM THICK PLATE
LIAIERNL EQUNALENT TO THAT OF LINE—PIPE FOR FABRICATiON.
IN CASE CALCULATED H EXCEEDS THE MAXIMUM VALUE, CONCRETE

PEDESTAL SHALL BE RAISED ACCORDINGLY.
DETAIL-M
MAX. VERTICAL LOAD = 750Kg

4 27.06.2011 REAFFIRMED AND ISSUED AS STANDARD tkti(RSB) kscp (ATD)(VKB) (DM)
3 17.03.2006 REVISED AND ISSUED AS STANDARD SR SS MRC VJN
No. by by Approved by
Format No. 8-00-0001-F4 Rev° Copyright EIL - All rights reserved

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DATA SHEET NO.

DATA SHEET FOR

Client : GIGL Dept. /Sect. : 11/42

SERVICE NATURAL GAS

Refer 6-44-0052 and Addendum to

INSTALLATION ABOVE GROUND

ASTM A352 Gr. LCC/ ASTM A

DISC LOOSE PLUG TYPE STELLITED

BONNET BOLTS ASTM A 320 GR. L7

BONNET NUTS ASTM A 194 GR. 4 / Gr.7

A 07.09.12 Issued for Bids SYG SRG MSG

Client : GIGL Dept. /Sect. : 11/42

SERVICE NATURAL GAS

Refer 6-44-0052 and Addendum to

INSTALLATION ABOVE GROUND

DISC LOOSE PLUG TYPE STELLITED

BODY SEAT RENEWABLE/

BONNET BOLTS ASTM A 320 GR. L7

BONNET NUTS ASTM A 194 GR. 4 / Gr.7

A 07.09.12 Issued for Bids SYG SRG MSG

Client : GIGL Dept. /Sect. : 11/42

SERVICE NATURAL GAS

Refer Spec. No. 6-71-0017 and

INSTALLATION ABOVE GROUND

TYPE SWING CHECK TYPE

BODY SEAT RENEWABLE/ NON-

DISC HINGE ASTM A 352 LCC/ SS 304/ SS316

HINGE PIN NO CASTING SS 304/ SS316

COVER GASKET SP-WND SS316-GRAFOIL FILTER

COVER NUTS ASTM A 194 GR. 4 / Gr.7

A 06.09.12 Issued for Bids SYG SRG MSG

Client : GIGL Dept. /Sect. : 11/42

SERVICE NATURAL GAS

Refer Spec. No. 6-71-0017 and

INSTALLATION ABOVE GROUND

BODY SEAT RENEWABLE/

DISC HINGE ASTM A 352 LCC/ SS 304/ SS316

HINGE PIN NO CASTING SS 304/ SS316

COVER GASKET SP-WND SS316-GRAFOIL FILTER

COVER NUTS ASTM A 194 GR. 4 / Gr.7

A 06.09.12 Issued for Bids SYG SRG MSG

esglkukµHkfVaMk ikbiykbu ifj;¨tuk

DATA SHEET FOR SCRAPER TRAP

B 06.09.12 REVISED & RE-ISSUED FOR BIDS SG SRG/ NR MSG

A 27.08.12 ISSUED FOR BIDS SG SRG/ NR MSG

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

1. 36” OD MAINLINE (010-PL-00-101) DT PALANPUR & RT BATHINDA

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

2. 36” OD MAINLINE (010-PL-00-101) IP 01, IP 02, IP 03, IP 04 & IP 05

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

3. 24” OD CHITTORGARH SPURLINE (025-PL-00-104)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

4. 12” NB SPURLINES UDAIPUR (037-PL-00-102), HISSAR (038-PL-00-112) & JODHPUR (014-PL-00-105)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

5. 18” NB BHIWADI SPURLINE (017-PL-00-107)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

6. 8” NB ALWAR SPURLINE (031-PL-00-108)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

7. 18” NB ROHTAK SPURLINE (019-PL-00-109)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

8. 18” NB GGSRL SPURLINE (021-PL-00-111)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

1 Barrel 8 Pressure Relief Valve